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1 CHECK OUT OUR WEBSITE SOME TIME FOR PLENTY OF ARTICES ABOUT SELF DEFENSE, SURVIVAL, FIREARMS AND MILITARY MANUALS. Thank yu fr purchasing ur ebk package.

2 SUBCOURSE QM3503 EDITION A DIRECT FUEL SYSTEM SUPPLY POINT OPERATIONS

3 DIRECT FUEL SYSTEM SUPPLY POINT OPERATIONS Subcurse Number QM 3503 EDITION A United States Army Cmbined Arms Supprt Cmmand Frt Lee, Virginia Credit Hurs Editin Date: September 1993 SUBCOURSE OVERVIEW This subcurse is designed t teach yu hw t identify the cmpnents f a fuel system supply pint (FSSP); perfrm and supervise preventive maintenance checks and services (PMCS) n the cmpnents f an FSSP; direct site preparatin, layut, and assembly f an FSSP; and perfrm emergency repair f cllapsible strage tanks. There are n prerequisites fr this subcurse. This subcurse reflects the dctrine which was current at the time that it was prepared. In yur wn wrk situatin, always refer t the latest fficial publicatins. Unless therwise stated, the masculine gender f singular prnuns is used t refer t bth men and wmen. TERMINAL LEARNING OBJECTIVE ACTION: CONDITION: STANDARD: Yu will identify the cmpnents f an FSSP; perfrm and supervise PMCS n the cmpnents f an FSSP; direct site preparatin, layut, and assembly f an FSSP; and perfrm emergency repair f cllapsible strage tanks in accrdance with FM Yu will have infrmatin and extracts in this subcurse that were derived frm FM T demnstrate cmpetency f this task, yu must achieve a minimum f 70 percent n the subcurse examinatin. i QM3503

4 TABLE OF CONTENTS Sectin Subcurse Overview... Page i Lessn: Direct Fuel System Supply Pint Operatins PART A - Organizatin and Operatin f a Fuel System Supply Pint PART B - Strage and Issue f Bulk Petrleum Practice Exercise Answer Key and Feedback Appendix A: List f Cmmn Acrnyms... A-1 Appendix B; Publicatin Extracts... B-1 FM Petrleum Supply Pint Equipment and Operatins, Octber 1986 Use the abve publicatin extracts t take this subcurse. At the time that we wrte this subcurse, this was the current publicatin. In yur wn wrk situatin, always refer t the latest publicatins. QM3503 ii

5 LESSON DIRECT FUEL SYSTEM SUPPLY POINT OPERATIONS Critical Tasks: LESSON DESCRIPTION: OVERVIEW In this lessn, yu will learn hw t identify the cmpnents f an FSSP; perfrm and supervise PMCS n the cmpnents f an FSSP; direct site preparatin, layut, and assembly f an FSSP; and perfrm emergency repair f cllapsible strage tanks. TERMINAL LEARNING OBJECTIVE: ACTION: CONDITION: STANDARD: REFERENCE: Yu will identify the cmpnents f an FSSP; perfrm and supervise PMCS n the cmpnents f the FSSP; direct site preparatin, layut, and assembly f an FSSP; and perfrm emergency repair f cllapsible strage tanks. Yu will be given infrmatin and extracts in this lessn that were derived frm FM T demnstrate cmpetency f this task, yu must achieve a minimum f 70 percent n the subcurse examinatin. The material cntained in this lessn was derived frm the fllwing publicatin: FM INTRODUCTION As the petrleum sectin supervisr, yu must ensure that persnnel use equipment prperly and that they maintain fuel accuntability in the field. T d this, yu must be familiar with the peratin f the FSSP. The FSSP is the Army's primary means fr the receipt, strage, and issue f bulk petrleum prducts in a tactical envirnment. It is lcated within the Class III fuel system supply pint. In this lessn, yu will learn hw t identify the cmpnents f an FSSP; direct site selectin, layut, and assembly f an FSSP; perfrm and supervise PMCS; and perfrm emergency repair f cllapsible strage tanks. 1-1 QM3503

6 PART A - ORGANIZATION AND OPERATION OF A FUEL SYSTEM SUPPLY POINT 1. Fuel System Supply Pint Cmpnents. The FSSP is the Army's primary means fr the receipt and strage f bulk petrleum and fr its issue t cmbat frces under tactical cnditins. The FSSP is nt issued as a cmplete system. The majr cmpnents are issued as separate items f equipment t add t the flexibility f the system. The number f majr cmpnents depends n the size and cnfiguratin f the system. An FSSP nrmally cnsists f-- a receiving manifld, tw 350-gallns per minute (GPM) pumping assemblies, tw 350-GPM filter/separatrs, six 10,000-galln cllapsible tanks, six bttm lading pints, tw 500-galln cllapsible drum filling pints, and six 5-galln can and 55-galln drum filling and vehicle refueling pints. Apprximately 2,400 feet f hse and nine types f fitting assemblies cnnect these fuel system cmpnents. When yu requisitin an FSSP, yu receive nly the hses, fitting assemblies, and tls t cnnect the abve cmpnents. Figure 1-1 shws a typical FSSP layut, and Figure 1-2 lists the cmpnents. a. Receiving Manifld. The receiving manifld cnsists f a wye and tee assembly (reducing frm 4 t 3 inches), lengths f 3-inch suctin hse, and 3-inch gate valves as shwn in Figure 1-1. With this manifld, the FSSP can receive prduct frm mre than ne transprter at a time. It als prvides a way t switch frm ne supply surce t anther. Use grunding equipment whenever yu receive fuel thrugh the manifld, because cntact between the receiving manifld and the grund is nt perfect. b. 350-GPM Pumping Assemblies. The FSSP nrmally has tw 350-GPM pumps. Use the 350-GPM pumps t mve fuel frm the supply surce t strage tanks. Als, use the pumps t mve fuel frm strage tanks t the dispensing pint. c. 350-GPM Filter/Separatrs. Use the vertically munted, 350- GPM filter/separatrs in each FSSP t remve entrained water and slid cntaminants frm the fuel befre pumping it int vehicles r cntainers. There are nrmally tw filter/separatrs per supply pint. QM

7 Figure 1-1. Typical fuel system supply pint layut 1-3 QM3503

8 Figure 1-2. Fuel system supply pint cmpnents QM

9 Figure 1-2. Fuel system supply pint cmpnents (cntinued) d. 10,000-Galln Cllapsible Tanks. The FSSP nrmally has six 10,000-galln cllapsible tanks t stre fuel. Each tank uses ne hse line manifld assembly with tw-tee fittings and ne hse line manifld assembly with ne-tee fitting. The manifld, as shwn in Figure 1-3, has tw rising-stem, duble-acting gate valves t cntrl the flw f fuel int and ut f the cllapsible tank. e. Bttm Lading Pints. The fuel system has six 3-inch bttm lading pints t lad fuel int tank semitrailers. Each bttm lading pint cnsists f a tee assembly (reducing frm QM3503

10 t 3 inches) cupled t a 3-inch, cam-lcking cupling valve fllwed by 25 feet f 3-inch discharge hse cupled t a 3-inch, cam-lcking cupling valve as shwn in Figure 1-1. Figure 1-3. Hse line manifld assemblies f. 500-Galln Cllapsible Drum Filling Pints. There are tw 500-galln cllapsible drum filling pints in the FSSP. Each pint cnsists f a tea assembly (reducing frm 3 t 1 1/2 inches) cupled t a 1 1/2-inch, cam-lcking cupling valve. Fllwing this is 25 feet f 1 1/2 inch discharge hse cupled t a 1 1/2-inch, camlcking cupling valve as shwn in Figure 1-3. Yu can als use the pressure cntrl (which is nt a cmpnent f the FSSP) fr the filling peratin. The inlet f the pressure cntrl attaches t the dwnstream end f the 1 1/2-inch discharge hse. The 5-ft length f pressure cntrl discharge hse cnnects frm the cntrl utlet t the drum elbw cupler valve as shwn in Figure 1-1. QM

11 g. 5-Galln Can and 55-Galln Drum Filling and Vehicle Refueling Pints. There are six 5-galln can and 55-galln drum filling and vehicle refueling pints in the FSSP. Each pint cnsists f a tee assembly (reducing frm 2 inches t 1 inch) fllwed by 25 feet f 1- inch discharge hse cupled t a 1-inch aluminum nzzle as shwn in Figure Hses, Fitting Assemblies and Accessries, and Tls. The FSSP uses suctin and discharge hses, varius types f fitting assemblies and accessries, and tls. The fllwing subparagraphs describe these cmpnents: a. Suctin and Discharge Hses. The tw types f hse assemblies used in the FSSP are suctin hard hse assemblies and discharge cllapsible hse assemblies. Each hse assembly has a male cupling (with a dust cap) n ne end and a female cupling (with a dust plug) n the ther end. Figure 1-1 shws where t use the lengths f hses. Use the dust caps and plugs when the hse sectins are nt cnnected t the system. b. Fitting Assemblies. The FSSP uses nine types f fitting assemblies, as shwn in Figure 1-4, t cnnect hse sectins, valves, and cmpnents. Assembly F cnsists f three quick-acting valve sizes. Keep dust caps and plugs n the assemblies when they are nt in use. T prevent lss, attach dust caps and plugs t the hse fittings with a chain. Ensure that all fittings have gaskets. Figure 1-1 shws the lcatin f each fitting assembly. c. Accessries and Tls. The FSSP cmes with accessries and tls s that yu can cnnect it t different fuel transprters, ther pumping assemblies, r pipelines. Yu als can use the accessries and tls t cnnect the FSSP cmpnents in many cmbinatins; The tls used t repair hse assemblies include a hse clamp lcking tl, buckles, and bandings. The accessries include an adapter fr cnnecting a tank car t a hse assembly, a pipe clamp cupling, and a pipe cupling fr cnnecting the FSSP t a pipeline. There are als reducers fr cnnecting different size hses, cupling halves (flanged and threaded) t make a number f cnnectins, gate valves, and wye fittings. 1-7 QM3503

12 Figure 1-4. Fuel system supply pint fitting assemblies QM

13 3. FSSP Use. Use the FSSP at distributin pints t prvide strage facilities fr transferring bulk fuel frm ne means f transprt t anther. Use the FSSP at dispensing facilities fr bulk reductin r fuel delivery t using vehicles. The FSSP can receive prduct frm tank trucks, railway cars, pipelines, hse lines, and aircraft. Since it can als receive fuel frm cean tankers, it is capable f supprting beached peratins. It can stre 60,000 gallns f bulk petrleum. It can stre even mre if yu add additinal r larger cllapsible tanks. Hwever, this expansin requires additinal hses, fitting assemblies, and valves. Yu easily can mve the FSSP frm ne place t anther and divide it in half t handle tw different types f fuels at tw different lcatins as shwn in Figure 1-5. Yu als can change it t a 10-pint, rapid-refueling system fr rtary aircraft. T perfrm this functin additinal equipment is required. 4. Mvement f Equipment. Yu can take dwn mst f the equipment withut fllwing prcedural steps r guidelines. D it as quickly and simply as yu can, but avid spills and accidents. First, drain the fuel frm the 10,000-galln cllapsible tanks int the hse system. Clse the valves at each tank s that the fuel des nt flw back int them. Place a cntainer under each tank drain prt, and drain the fuel left in the tank. Stw the tanks in their carrying cases. Nw, starting at the receiving pint, drain the fuel frm the receiving side f the system, int the discharge side. Keep the discharge pump running fr suctin. Discnnect the hse assemblies, and stw them in cntainers (when available). Be sure t install all dust caps and plugs n the hse assemblies as yu dismantle them. Discnnect the discharge pump, and drain the fuel frm the hse assemblies n the discharge side f the system. Discnnect the hse assemblies, and stw them in cntainers (when available). 1-9 QM3503

14 Figure 1-3. Suggested layut fr a fuel system divided fr handling tw different fuels r fr mving QM

15 5. Site Selectin. Yur next-higher headquarters will assign yu an area f peratin. Chse yur site within that area. Hwever, d nt chse a site that is near imprtant cmmunicatins and ppulatin centers that may be enemy targets. Recnniter yur chsen site befre the arrival f equipment and persnnel. Lcate the site as clse t supprted units as dispersin factrs, surces f supply, and the tactical situatin permit. Prvide at least tw strage areas with balanced stcks in each. Use vacated frward sites r existing facilities when yu can. There shuld be tw large areas (ne in the frnt and ne in the rear) that yu can use fr truck parking. Figure 1-6 depicts an ideal site as well as sites that yu shuld nt use. a. Fuel System Supply Pint Cnsideratins. When yu select the FSSP site, cnsider cver and cncealment, rad nets, distances between items, terrain, and site-preparatin requirements. Cnsider dispersin factrs, and make sure that the site is suitable fr the fuel system layut. (1) Cver and Cncealment. Select a site fr the cllapsible tanks, pumps, and filter/separatrs that is in the wds r in a tree line where the natural shadws disguise the telltale shapes. Use camuflage nets if yu nave them. When yu lay hse line, make use f natural terrain cnturs and vegetatin t break up straight lines. One way that yu can d this is t cut branches and stick them int the earth under the hse, and then weigh them dwn with the hse line. Where yu have deep grass r ther vegetatin, bend it ver the hse line t hide the hse s that it is nt seen frm the air. (2) Rad Nets. Chse a site fr the receiving, truck bttm lading, and vehicle refueling pints next t a rad in the Class III fuel system supply pint. Yu can then lad r unlad trucks and refuel vehicles withut leaving the rad nets in the supply pint. (3) Distances Between Items. Yu must cnsider the distances between items when yu select the sites fr the equipment in the FSSP. In ther wrds, hw far apart shuld yu put yur cmpnents? Figure 1-7 shws the usual distances between them. These distances are apprximate, and they can vary with the terrain, natural cver, cncealment, hse available, and rad nets. Hwever, yu must put the 10,000-galln cllapsible tanks at least 40 feet apart. Chse a site that is large enugh t meet the needs f prduct supply, but that is nt s large that the handling peratin becmes inefficient QM3503

16 Figure 1-6. Site selectin guidelines fr a Class II fuel system supply pint. (4) Terrain. Select level terrain fr the FSSP. Ensure that the site is well drained t prevent water damage. Avid lw areas r fill them s that vaprs d nt cllect. Never chse a site that is uphill r dwnstream frm installatins that wuld be in the path f escaping fuel. Lk fr a tank site withut slpes. A large slpe may cause filled tanks t rll sideways, backward r frward. Put the pumps and filter/separatrs n level grund. Try t place the discharge pump at a lwer level than the cllapsible tanks s that there will be gd suctin t the pump. QM

17 Figure 1-7. Usual distances between fuel system supply pint cmpnents (5) Site Preparatin. The three majr items f equipment that yu have t deal with in the FSSP are the 10,000-galln cllapsible tanks, the 350-GPM pumping assemblies, and the 350-GPM filter/separatrs. Slpe the tank sites gently tward the manifld end t help drain the tanks prir t remving them. Slpe the site fr each tank n mre than 3 t 6 inches in the directin f the tank's fill prt. Build a fire wall arund each tank. Make sure that it is large enugh t hld the cntents f the tank and 1 ft f freebard. T d this, build the fire wall 3 feet high and 18 inches wide at the tp. Make the inside dimensins f the fire wall 26 feet by 26 feet. Maintain a distance f 3 feet frm the edge f the tank t the base f the fire wall. If engineer persnnel prepare the site, give them this infrmatin. Clear the pump and filter/separatr sites f dry grass, leaves, and trash. b. Standard Fuel System Supply Pint Arrangements. Lay ut the FSSP t take advantage f the terrain, natural cver, cncealment, available hse, and rad nets. If yu must handle tw types f fuels, such as jet prpulsin 8 (JP-8) and mtr gasline (MOGAS), yu may have t divide the fuel system as shwn in Figure 1-5. Figures 1-8 thrugh 1-11 shw sme typical arrangements. If nne 1-13 QM3503

18 f these arrangements is suitable, yu may change the arrangements t fit yur needs. Figure 1-8. U-arrangement Figure 1-9. Rectangular arrangement QM

19 Figure Semicircular arrangement Figure V-arrangement 1-15 QM3503

20 c. Fuel System Supply Pint Cmpnents. The best way t lay ut the FSSP is t put the cllapsible tanks in their prepared sites first. Put the pumping assemblies and filter/separatrs in place. Lay ut all the fitting assemblies and hses. Then make the cnnectins and attach the fuel- and il-servicing nzzles. Make sure that yu have placed the cmpnents t cnfrm t the arrangement that yu chse fr the fuel system. Lay ut the FSSP cmpnents as discussed in the fllwing subparagraphs: (1) 10,000-Galln Cllapsible Tanks. T prepare the 10,000- galln cllapsible tanks, place the tanks at the prepared sites s that when yu remve them frm their cntainers and unfld them, they are in psitin. DO NOT step n the tanks as yu unfld them. Inspect the tank fabric fr cuts, snags, r ther damage. Be sure that the tank filler and discharge, drain fitting, and vent pipe assemblies are in gd wrking rder. (2) 350-GPM Pumping Assemblies. After yu put the 350-GPM pumping assemblies in place, lwer the retractable supprt and chck the wheels f each pump. Then drive a grund rd int the grund near each pump. Attach a grund cable frm the rd t the pump frame. (3) 350-GPM Filter/Separatrs. After yu place the 350-GPM filter/separatrs in psitin, put shims under the skids t help level them. Drive a grund rd int the grund near each filter/separatr, and attach a grund cable frm each rd t each unit. Finally, cnnect a hse r a pipe t the autmatic water drain prt t carry water away frm the unit. (4) Fitting Assemblies and Hses. Put all fitting assemblies and hses in their prper places. Ensure that all suctin hses are n the receiving side f the system and that all discharge hses are n the dispensing side. Place 3-inch discharge hse at the tank truck bttm lading pints. Place 1 1/2-inch discharge hse at the 500-galln cllapsible drum filling pints and 1-inch discharge hse at the vehicle refueling pints. Nw, starting at the cllapsible tanks, cnnect all hse and fitting assemblies. Make sure that yu leave all dust plugs and caps n the hses and fitting assemblies until yu cnnect them int the system. (5) Fuel- and Oil-Servicing Nzzles. Attach the six nzzles t the 1-inch discharge hse assemblies. Make sure that each nzzle dust cap cvers the sput f each nzzle. Make a supprt fr the nzzles s that they d nt lie n the grund when they are nt in use. d. Safety and Security Items. Once yur supply pint is set up, yu must take steps t make it safe and secure. The fllwing subparagraphs describe these steps: QM

21 (1) Checkpints. Set up checkpints at the perating area entrance and exit. Give persnnel entering the area a safety briefing at the entrance checkpint. Refer t the extracts f FM 10-69, Chapter 9, in Appendix B at the end f this subcurse fr a fire preventin presentatin that yu can make at the checkpint. Use the checkpints nt nly t cntrl the vehicles ging in and ut, but t accunt fr the receipt and issue f petrleum in the supply pint as well. (2) Fire Plan. Develp a fire plan. Fr details, refer t the extracts f FM 10-69, Chapter 9, in Appendix B at the end f this subcurse. (3) Signs. Yu must set up many different types f signs in the area f peratin. Place signs identifying NO SMOKING areas and dangerus areas thrughut the supply pint. Yu als must set up speed, cntrl, and traffic directin signs. 6. Operatins. Befre yu can wrk at an FSSP, yu must understand hw petrleum flws thrugh it. Figure 1-12 shws the prduct mving thrugh the FSSP. Yu shuld knw where t receive fuel, which items f equipment transfer and stre fuel, and where and hw yu issue fuel. a. Flw Thrugh the Fuel System Supply Pint. The first step is t inspect the fuel when it arrives. The prduct then enters the system thrugh the receiving manifld. It usually mves under the suctin prvided by ne f the tw 350-GPM pumps used as a receiving pump. (The prduct als may mve under psitive pressure frm a transprter, pipeline, r hse line.) Yu may have bth filter/separatrs installed n the delivery side f the system. In this case, the receiving pump distributes the prduct directly t the tanks thrugh the delivery side f the system, and yu use the ther 350-GPM pump t draw fuel frm the tanks and discharge it thrugh the tw filter/separatrs, int the hse header system. Alternatively, yu may have nly ne filter/separatr installed n the receiving side f-the system. In this case, the receiving pump distributes the prduct t the receiving filter/separatr and then t the cllapsible tanks. Frm this pint n, regardless f whether yu have bth filter/ separatrs r nly ne installed n the receiving side f the system, the flw f the fuel is the same except that the fuel is drawn thrugh nly ne filter/separatr n the discharge side f the system when ne filter/separatr, rather than bth, is installed n the receiving side f the system QM3503

22 Yu als can use nly ne 350-GPM pump t draw the prduct frm the supply surce, directly t the discharge side f the system, bypassing the strage tanks. Figure Receiving prduct int the fuel system supply pint frm tank vehicles b. Fuel System Supply Pint Operatins. Fr a single shift, yu need eight wrkers t perate the FSSP efficiently. Place them at certain strategic pints in the peratin as described in the fllwing subparagraphs. (1) Receiving Side. Assign tw wrkers t the receiving manifld. Make them respnsible fr transferring bulk petrleum frm the transprter t the fuel system. They perate all valves at the receiving pint and make all necessary hse cnnectins. QM

23 (2) Pumps and Valves. Assign three wrkers t the pumps and cntrl valves. Have ne wrker perate each pump. Once the pumps are started, ne wrker can mnitr them. Having ne wrker mnitr the pumps enables the ther tw wrkers t devte their full time t valve cntrl and fuel flw prblems. Have ne f these tw wrkers cntrl the valves n the discharge and receiving manifld f the cllapsible tanks. (3) Dispensing Side. Assign three wrkers t the delivery side f the system. This cnsists f six 5-galln can and 55-galln drum and vehicle filling pints and tw 500-galln cllapsible drum filling pints. Make them respnsible fr dispensing petrleum and cntrlling the fuel flw. Have them prepare the varius filling pints, perate the cntrl valves, and make all necessary hse cnnectins. When filling tank vehicles, have the truck driver help dispense the fuel. c. 500-Galln Cllapsible Drums. Yu need nly tw wrkers t fill the drums directly frm the FSSP. The psitining and the tasking f the crew vary with each f these methds. When filling drums directly frm the FSSP, assign ne wrker t the cntrl valves f the filling pint. Make this wrker respnsible fr cntrlling the flw f petrleum t the drums. Assign the ther wrker t the drums. Make this wrker respnsible fr preparing the drums fr filling, making all cnnectins, and mnitring the filling peratins. d. 55-Galln Drum Filling Operatins. When yu use six fuel- and il-servicing nzzles n the FSSP, yu need 10 wrkers t d the jb well. Place ne wrker at each nzzle. Yu als need tw wrkers t bring empty drums t the filling pints and tw wrkers t remve full drums t the bulk reductin strage area. If yu have a frklift, use it t mve the full drums t the strage area. Make the six wrkers at the servicing nzzles respnsible fr bnding the nzzles t the cntainers and filling the drums t the prper level. e. 5-Galln Can Filling Operatins. When yu fill the cans directly frm the FSSP, use essentially the same peratin as fr the 55-galln drum. 1. Strage Practices. PART B -STORAGE AND ISSUE OF BULK PETROLEUM Yu shuld fllw a number f practices when string bulk petrleum. The fllwing bullets list these practices: 1-19 QM3503

24 Make sure that yu have a separate handling system fr each type f prduct that yu stre. Never mix varius fuels tgether, and never mix leaded and unleaded gasline. Install a filter/separatr in the supply line between the strage tanks and the dispensing pints. DO NOT stre yur hses in a way that will bend them sharply ver brackets. DO NOT leave hses lying n the grund where vehicles may run ver them. In additin, put dust caps and plugs n all hses nt in use. Drain any water in the cllapsible tanks thrugh the drain fitting assembly. Clean line strainers and nzzle screens daily. When yu remve a pressure nzzle screen, discnnect the adapter first. Repair r replace damaged strainers and screens at nce. Particles f rubber r lint in a screen may indicate a deterirating hse. Sediment, scale, r rust in the nzzle screen may indicate a filter element failure. Put dust caps n nzzles t keep dust, dirt, and sediment frm entering the nzzle sput and cntaminating the fuel. Run a string acrss the tp f cllapsible tanks s that yu d nt verfill them. Put the string 4 feet ff the grund fr 3,000-and 10,000-galln cllapsible tanks, 5 feet ff the grund fr 20,000-galln cllapsible tanks, and 6 feet ff the grund fr 50,000-galln cllapsible tanks. The tank is full when the tp f the tank reaches the string. Fllw the first-in, first-ut rule s that prducts d nt deterirate due t prlnged strage. Issue packaged prducts in damaged cntainers first, regardless f age. Inspect yur facilities and peratins regularly. Keep recrds f inspectins, tests, checks, tank cleaning, and maintenance. Fllw up and crrect deficiencies. 2. Inspectins. Inspectins are the key t finding ut hw well yur FSSP is perfrming. They prvide firsthand infrmatin n hw the equipment and prducts are maintained frm day t day. Inspectins let yu make n-the-spt crrectins. They als give yu infrmatin n the availability f required publicatins, accuracy f supply recrds QM

25 and prcedures, supply ecnmy practices, care f tls and equipment, and status f authrized stck levels f equipment and repair parts. Perfrm the fllwing steps when inspecting yur FSSP: Inspect the cllapsible tanks and hses in yur supply pint each day fr signs f leaks, tears, punctures, unusual wear, and fabric deteriratin. Inspect the perating equipment in the supply pint daily t evaluate peratr maintenance and ensure that the equipment is in gd wrking rder. Inspect fire fighting equipment and drainage facilities weekly t see that they are in gd cnditin. Make sure that the strage area is free f trash, weeds, and ther cmbustible material. Survey the traffic cntrl system ften t ensure that traffic is ruted efficiently. Ensure that unnecessary equipment in the area des nt hinder traffic mvement r access t fire fighting equipment. 3. Filter/Separatrs Preventive Maintenance Checks and Services. Filter/separatrs keep the prduct clean and free f water at the Class III fuel system supply pint. The fllwing steps describe the PMCS necessary t maintain the filter/separatrs: Test the accuracy f the pressure differential indicatr nce a year. Check the filter sumps each day. Remve any water. Keep a daily recrd f pressure differential readings. Pressure differential with a clean, new element is usually 2.5 punds per square inch (psi) r less. It shuld increase slwly with use. Inspect the filter elements immediately if there is a sudden, significant drp in the pressure differential. It may mean that a filter element has ruptured. Check the new filter elements if there is n increase in the pressure differential after several mnths f peratin. Yu may find that the elements were installed imprperly r that sme have ruptured. Change the filter elements at nce when the reading n the pressure differential indicatr is in the red (35 psi 1-21 QM3503

26 and up). Change them at the end f the daily peratin when the reading is in the yellw (20 t 35 psi). Change the filter elements at least every 24 mnths r when an inspectin indicates that they are ruptured r were nt installed prperly. Stencil the mnth and the year that yu change the filter elements n the tp f the filter/separatr. Check the perfrmance f all filter/separatrs, regardless f the prduct in service, every 30 days thrugh the submissin f samples t a designated labratry. 4. Prduct Cnslidatin and Circulatin. Cnslidate r circulate prduct by mving it frm ne FSSP strage tank t anther. Cnslidate stcks s that several strage tanks are full and several are empty. Then, yu can receive and issue large amunts f prduct n shrt ntice and cut dwn n tank switching during receipt and issue. Circulate yur stck s that the heavier prduct prtins d nt settle t the bttm f the tank and the light prtins d nt cme t the tp. Circulatin ensures a gd mixture f all the additives in the fuel. Perfrm the fllwing prcedures fr cnslidating fuel at the FSSP: Grund the FSSP equipment. Then pen the cllapsible tank manifld valves frm which yu are transferring prduct. Open the suctin valve n the 350-GPM pumping assembly and the manifld valves n the cllapsible tank that will receive the prduct. Ensure that all the ther valves between the tw cllapsible tanks are pen. Make yur daily preventive maintenance checks n the pump. Start the pump, and idle it fr three t five minutes. Open the discharge valve n the pump, and increase the pump speed t the perating level. Cntinue pumping this way until yu have finished the transfer. Figure 1-13 shws the prduct mving thrugh the FSSP. Idle the pump back fr three t five minutes befre yu shut it ff. Clse the discharge valve n the pump and the manifld valves n the cllapsible tanks while the pump is idling. Clse the suctin valve n the pump. QM

27 Figure Cnslidating r circulating prduct in the fuel system supply pint 5. Emergency Tank Repair. If any f the cllapsible tanks develp a leak, repair them at nce with emergency repair items. There are tw repair methds. One uses sealing plugs, and the ther uses sealing clamps. The ne that yu use depends upn the size f the cut, tear, r rupture. Whatever methd yu use, ensure that yu put n rubber glves and the prtective hd befre starting the repair peratin. a. Sealing Plugs. Use a sealing plug if the hle in the tank is three-eighths f an inch r smaller. Figure 1-14 and the fllwing steps shw hw t repair a tank with a sealing plug: Insert a wd plug in the hle t stp the leak temprarily. Then use the rtary cutter t cut a clean edge arund the hle QM3503

28 Figure Applicatin f sealing plugs Push the cne-shaped end f a sealing plug assembly thrugh the hle, and pull the sealing plug tight against the interir f the tank wall. Tighten the sealing plug assembly nut with pliers, and cut ff the excess sealing plug assembly shank. b. Sealing Clamps. Use a sealing clamp if the hle is larger than three-eights f an inch. Repairs with sealing clamps are mre permanent than thse with sealing plugs. Sealing clamps use the tank skin as a gasket-type sealant until yu can send the tank t the general supprt maintenance facility. Yu may install sealing clamps when the tank is full, but install them as quickly as yu can. Perfrm the fllwing steps and thse shwn in Figure 1-15 t repair a sealing clamp: Select a sealing clamp. The bttm plate f the clamp that yu select shuld fit thrugh the tear at its narrwest dimensins, Slit the tear slightly t insert the clamp bttm plate if necessary. QM

29 Figure Applicatin f sealing clamps Fld the hinged stud dwn, and insert the bttm plate thrugh the rupture. Straighten the stud, and rtate the plate s that the lng dimensin f the rupture is alng the plate's length. Slide the upper plate f the sealing clamp ver the stud, and install and tighten the wingnut. 6. Dispsal f Excess. If yu are in the cntinental United States (CONUS) r an verseas activity and yu have an excess in bulk r packaged fuels f 500 gallns r mre per prduct grade, reprt the excess by sending a message t the Cmmander, United States Army General Materiel and Petrleum Activity (USAGMPA). Include in yur message the quantity, lcatin, type f prduct, natinal stck number (NSN), and latest labratry test results. If yu are in an verseas cmmand, als reprt the excess t the apprpriate Defense Fuel Supply Center (DFSC) field ffice r t the Jint Petrleum Office (JPO) QM3503

30 7. 10,000-Galln Cllapsible Tank Preventive Maintenance Checks and Services. A number f PMCS are necessary fr the 10,000-galln cllapsible tank. Within designated intervals, perfrm the befre (B), during (D), and after (A) PMCS in the rder listed, as shwn in Figure Figure ,000-galln cllapsible tank preventive maintenance checks and services QM

31 8. Issue Cnslidatin. Issuing bulk petrleum is perhaps yur mst imprtant respnsibility at the Class III fuel system supply pint. Yur purpse in the field is t get large quantities f petrleum t the units that yu supprt. In the theater f peratins, yu issue liquid petrleum in bulk as far frward as the tactical situatin permits. Usually, the units that yu supprt pick up bulk petrleum frm the supply pint in their wn vehicles. When yu use the FSSP, make yur bulk issues frm the bttm lading pints. The fllwing paragraphs discuss step-by-step prcedures fr issuing bulk petrleum t tank vehicles and tank cars: 9. Preliminary Prcedures. Yu shuld take a number f steps befre issuing bulk petrleum frm yur Class III fuel system supply pint. The fllwing subparagraphs discuss these preliminary steps: a. Issue Schedule Preparatin. Prepare an issue schedule befre any transprter arrives at the supply pint. Start by telling yur custmer hw much and what type f prduct yu have n hand. Then tell him when he can pick up prduct at the supply pint. If yur transprters are delivering the prduct, tell the custmer when it will arrive at his supply pint. Try t avid delays and interruptins when yu are scheduling issues. In ther wrds, d nt have mre transprters at yur supply pint than yu can handle at ne time. Als, ensure that yu have enugh prduct n hand t fill all yur rders. b. Equipment Inspectin. Ensure that the discharging equipment in the supply pint is in gd wrking cnditin. Inspect yur pumps, filter/separatrs, cllapsible tanks, hse, maniflds, valves, and fittings daily t see that they are free f leaks and cntaminatin. c. Transprter Sptting. When the transprter arrives at the supply pint, check the custmer's issue request t ensure that the transprter is authrized prperly. Psitin the transprter at an issue pint. d. Transprter Inspectin. Open the manhle r dme cver t inspect the transprter. As part f yur inspectin, perfrm the fllwing: Check inside and utside the tank fr hles, cracks, r lse plates. Ensure that there are n leaks in the tank. See that the tank munts prperly t the frame and is safe t perate n the rad QM3503

32 Inspect inside the tank fr cleanliness. If yu see residue such as rust, sand, r dirt n the bttm f the tank, reject the transprter and have it cleaned. Let nly authrized persnnel familiar with tank-cleaning prcedures and safeguards enter a tank. Check the tank interir fr freign bjects such as tls, blts, r ld seals. Have authrized persnnel remve bjects frm the tank. Sme bjects d nt cntaminate the prduct, but they may damage valves. Als, lk fr residual prduct in the tank. If yu see any, remve it befre yu fill the tank. Inspect the fuel delivery system f the transprter fr damage. On tank cars, check the dme, dme cver, bttm utlet chamber, and safety valve t ensure that they are in gd cnditin. See that the vent hles in the dme cver are pen and free f dirt. Ensure that the tank care utlet valve seats and seals prperly. T d this, first place a drain tub under the bttm utlet chamber. Open and clse the utlet valve several times by wrking the valve rd handle r handwheel lcated inside the dme. If the valve des nt seat prperly, reject the care. Reprt the malfunctin t the lcal transprtatin fficer fr scheduled repairs. In an emergency, yu may lad the tank car withut repairing the valve, but reprt the brken valve t the unit receiving the tank car s that unlading can be dne thrugh the dme. In any case, schedule the tank care fr repair as sn as pssible. Ensure that the utlet valve is clsed after yu check it. Ensure that the prduct last carried in the tank is the same as the prduct that yu are ging t put Int it. If yu think that it is necessary, flush the transprter tank with a small amunt f prduct t remve any traces f the last prduct as well as rust and scale. Cllect this prduct, and put it int a waste cntainer. QM

33 LESSON PRACTICE EXERCISE The fllwing items will test yur grasp f the material cvered in this lessn. There is nly ne crrect answer fr each item. When yu cmplete the exercise, check yur answer with the answer key that fllws. If yu answer any item incrrectly, study again that part f the lessn which cntains the prtin invlved. Situatin: Yu are a petrleum sectin supervisr checking the cmpnents f an FSSP which yu will use under nrmal perating cnditins. Use this situatin and Figure 1-17 t answer questins 1 thrugh Yu ensure that the FSSP has hw many 350-GPM pumping assemblies? A. One. B. Tw. C. Three. D. Fur. 2. Yur FSSP uses hw many different fitting assemblies? A. Tw. B. Five. C. Eight. D. Nine. 3. Yu can divide yur FSSP int hw many different lcatins? A. Tw. B. Three. C. Fur. D. Five. Figure Assembly 1-29 QM3503

34 4. The assembly shwn in Figure 1-17 is which f the fllwing types? A. Wye. B. Quick-acting valve. C. Reducer tee. D. Flanged wye and tee. 5. Hw many 4-inch adapter flanges t 3-inch male cuplings des the assembly shwn in Figure 1-17 cntain? A. One. B. Tw. C. Three. D. Fur. 6. Which f the fllwing prcedures is yur first step in mving the FSSP? A. Draining the fuel frm the 10,000-galln cllapsible tanks int the hse system. B. Clsing the valves at each tank s that fuel des nt flw back int the tanks. C. Draining fuel left in the tank int cntainers under the tank drain prts. D. Draining fuel frm the hse assemblies and discnnecting them. QM

35 Situatin: Yu are a petrleum sectin supervisr supervising the selectin f a site fr a Class III fuel system supply pint. Use this situatin and Figure 1-18 t answer questin 7. Figure Pssible site fr a Class III fuel system supply pint 7. Yu place yur receiving manifld the usual distance frm the receiving pump. This is a distance f hw many feet? A. 25. B. 50. C. 60. D. 75. Situatin: Yu are a petrleum sectin supervisr supervising the peratin f a Class III fuel system supply pint. Use this situatin t answer questin QM3503

36 8. Fr a single shift, yu need hw many wrkers t perate yur FSSP efficiently? A. Three. B. Fur. C. Eight. D. Nine. Situatin: Yu are a petrleum sectin supervisr supervising the receipt, strage, and issue f bulk petrleum. Use this situatin t answer questins 9 and When string bulk petrleum prducts, hw ften d yu clean line strainers and nzzle screens? A. Daily. B. Weekly. C. Mnthly. D. Quarterly. 10. Yu review yur persnnel's recrd f pressure differential readings. With a clean, new element, the pressure differential is usually hw many psi? A. 1.0 B. 1.5 r less. C. 2.0 D. 2.5 r less. QM

37 LESSON PRACTICE EXERCISE ANSWER KEY AND FEEDBACK Item Crrect Answer and Feedback 1. B. Tw. The FSSP is nt issued as a cmplete system. The majr cmpnents are issued as separate items f equipment t add t the flexibility f the system. The number f majr cmpnents depends n the size and cnfiguratin f the system. An FSSP nrmally cnsists f a receiving manifld, tw 350-GPM pumping assemblies, tw 350-GPM filter/separatrs, six 10,000-galln cllapsible tanks, six bttm lading pints, tw 500-galln cllapsible drum filling pints, and six 5-galln can and 55- galln drum filling and vehicle refueling pints. (Page 1-2, para 1) 2. D. Nine. Apprximately 2,400 feet f hse and nine types f fitting assemblies cnnect these fuel system cmpnents. When yu requisitin an FSSP, yu receive nly the hses, fitting assemblies, tls, and accessries t cnnect the abve cmpnents. (Page 1-2, para 1) 3. A. Tw. Yu can easily mve the FSSP frm ne place t anther and divide it in half t handle tw different types f fuels at tw different lcatins as shwn in Figure 1-5. (Page 1-9, para 3) 4. D. Flanged wye and tee. Figure 1-4 shws nine types f fitting assemblies used in the FSSP. The assembly shwn in Figure 1-17 is a flanged wye and tee assembly (Assembly A). (Page 1-8, Figure 1-4) 5. C. Three. Accrding t Figure 1-4, Assembly A has three 4-inch adapter flanges t 3-inch male cupling. (Page 1-8, Figure 1-4) 1-33 QM3503

38 Item Crrect Answer and Feedback 6. A. Draining the fuel frm the 10,000-galln cllapsible tanks int the hse system. Yur first step in mving the FSSP is t drain the fuel frm the cllapsible tanks int the hse system. (Page 1-9, para 4) 7. C. 60. Figure 1-7 shws the usual distances between FSSP cmpnents. Accrding t Figure 1-7, yu maintain a distance f 60 feet between the receiving manifld and the receiving pump. (Page 1-13, Figure 1-7) 8. C. Eight. Fr a single shift, yu need eight wrkers t perate the FSSP efficiently. Place them at certain strategic pints in the peratin. (Page 1-18, para 6b) 9. A. Daily. Clean line strainers and nzzle screens daily. When yu remve the screen in a pressure nzzle, discnnect the adapter first. Repair r replace damaged strainers and screens at nce, Particles f rubber r lint in a screen may indicate a deterirating hse. Sediment, scale, r rust in the nzzle screen may indicate filter element failure. (Page 1-20, para 1) 10. D Keep a daily recrd f pressure differential readings. The pressure differential with a clean, new element is usually 2.5 psi r less. It shuld increase slwly with use. (Page 1-21, para 3) QM