UFC 3-460-01

16 August 2010

UNIFIED FACILITIES CRITERIA (UFC)

DESIGN: PETROLEUM FUEL 

FACILITIES

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED
UFC 3-460-01

16 August 2010

UNIFIED FACILITIES CRITERIA (UFC)

CRITERIA FORMAT STANDARD

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the 

copyright holder.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND (Preparing Activity)

AIR FORCE CIVIL ENGINEER SUPPORT AGENCY

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location

 

This UFC supersedes UFC 3-460-01, dated 16 January 2004. 
UFC 3-460-01

16 August 2010

i 

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides 

planning, design, construction, sustainment, restoration, and modernization criteria, and applies 

to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance 

with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and 

work for other customers where appropriate. All construction outside of the United States is 

also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction 

Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.) 

Therefore, the acquisition team must ensure compliance with the more stringent of the UFC, the 

SOFA, the HNFA, and the BIA, as applicable. 

UFC are living documents and will be periodically reviewed, updated, and made available to 

users as part of the Services’ responsibility for providing technical criteria for military 

construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities 

Engineering Command (NAVFAC), and Air Force Center for Engineering 

and the Environment (AFCEE) are responsible for administration of the UFC system. Defense 

agencies should contact the preparing service for document interpretation and improvements. 

Technical content of UFC is the responsibility of the cognizant DoD working group. 

Recommended changes with supporting rationale should be sent to the respective service 

proponent office by the following electronic form: Criteria Change Request (CCR). The form is 

also accessible from the Internet sites listed below. 

UFC are effective upon issuance and are distributed only in electronic media from the following 

source:

• Whole Building Design Guide web site http://dod.wbdg.org/. 

Hard copies of UFC printed from electronic media should be checked against the current 

electronic version prior to use to ensure that they are current. 

______________________________________

JAMES C. DALTON, P.E.

Chief, Engineering and Construction 

U.S. Army Corps of Engineers

______________________________________

JOSEPH E. GOTT, P.E.

Chief Engineer

Naval Facilities Engineering Command

______________________________________

DENNIS FIRMAN

Director of the Air Force Center for Engineering 

and the Environment

Department of the Air Force

______________________________________

MICHAEL McANDREW

Director, Facility Investment and

 Management

Office of the Deputy Under Secretary of Defense

 (Installations and Environment)
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16 August 2010

ii

UNIFIED FACILITIES CRITERIA (UFC)

REVISION SUMMARY SHEET

Document: UFC 3-460-01

Superseding: UFC 3-460-01, 16 January 2004. Note that UFC 3-460-01, 16 January 

2004 did not make any changes to MIL-HDBK-1022, 1 November 1999.

Description of Changes: This update to UFC 3-460-01 incorporate changes to the 

design requirements for fuel facilities. These changes are based on lessons learned 

from the previous guidelines, new technologies, updated requirements by the services 

for fuel handling and quality, and new regulations and other reference documents. 

Incorporation of these changes will decrease the life-cycle costs by ensuring the 

integrity of the fueling systems during operations and decreasing maintenance 

requirements. These changes include, but not limited to updating the references, and 

the requirements for:

• Physical Security (Paragraph 2-6)

• Electrical Classifications (Paragraph 2-12)

• Fire Protection (Paragraph 2-15) 

• Canopies (Paragraph 3-8)

• Fuel Filtration (Table 4-1)

• Isolation Valves (Paragraph 3-6.7)

• Tanks (Paragraphs 8-4 Thru 8-10)

• Aboveground Tank Spill Containment Systems (Paragraph 8-14) 

• Tank Appurtenances, (Table 8-1)

• Coating Systems, (8-3.9, 9-6 Thru 9-9)

• Piping Systems (paragraph 9-2.1). 

This update also includes hyperlinks between the Table of Contents to the document, 

and the document to the glossary and references.

Reasons for Changes: 

• Requirements for the fueling systems and related facilities have changed 

due to the type of fuels currently used, and the quality requirements for 

these fuels. The quality requirements for these fuels are set by the Naval 

Air Systems Command, Naval Sea Systems Command, Air Force 

Petroleum Office, and the Army Petroleum Office.

• Many of the changes are from lessons learned from design, construction, 

maintenance and operations of the fuel facilities. 

• Many of the references have changed or out dated.

Impact: The changes to this UFC will impact the design and cost of fuel facilities. 

However, the following benefits should be realized.

• Ensure that the fuel quality issued to the DoD aircraft, trucks, ships, and 

vehicles is such that no damage is realized to all of the DoD assets 
UFC 3-460-01

16 August 2010

iii

• By ensuring that all fuel facilities will be standardized throughout the triservices. 

• Decrease the amount of maintenance and repair required on the fuel 

facility system.

Non-Unified Items: There are a few items that are either Navy, Air Force or Army 

specific. The list below summarizes these items, along with the justification for it to be 

Service Specific:

• The Navy requires the use of a fusible link butterfly valve at the inlet to 

truck fillstand and on supply and return risers at aircraft direct fueling 

stations. The Navy’s position for fusible link valves is primarily because 

JP-5, which is primarily used by the Navy, does not have the Static 

dissipater additive (SDA), so it is more likely to spark during transport thru 

pipelines and equipment than any other fuel. (Refer to paragraph 2-

3.14.3). The fusible link will shut if there is a fire or other high-temperature 

event. Also, the Navy’s aircraft direct fueling stations are designed to hot 

refuel aircraft, so the fusible link will also protect the aircraft if there is a 

high-temperature event between the tank and the fusible link.

• The Air Force allows the use of internally coated filter separators and 

piping from the filter/separators to the skin of the aircraft. Since it is Air 

Force policy to always filter the fuel at the skin of the aircraft, any paint 

and carbon particles in the fuel will be filtered before entering the aircraft. 

The Navy does not filter at the skin of the aircraft, therefore the filterseparator must be either aluminum or stainless steel, and the piping from 

the filter-separator to the aircraft is to be stainless steel.

• This UFC references Service-Specific documents, which the tri-service 

fuel community does not oversee. Also, each service has its own 

requirements for fuel quality and operations. 
UFC 3-460-01

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iv

ABSTRACT

This guidance is for individual project planning and for preparing engineering and 

construction documentation. Basic guidance is provided to professional facility 

planners, engineers, and architects for use in designing liquid fueling and dispensing 

facilities, liquefied petroleum gas facilities, and compressed natural gas facilities. 

Included are basic requirements for the design of fueling systems; the design of 

receiving, dispensing, and storage facilities; ballast treatment and sludge removal; 

corrosion and fire protection; and environmental requirements.
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TABLE OF CONTENTS

CHAPTER 1 - INTRODUCTION ..................................................................................... 1

1-1 SCOPE ...................................................................................................... 1

1-2 USE OF UFC............................................................................................. 1

1-3 PURPOSE OF CRITERIA.......................................................................... 1

1-4 DEPARTMENT OF DEFENSE (DoD) FUELS FACILITY ENGINEERING 

PANEL....................................................................................................... 1

1-5 SERVICE HEADQUARTERS SUBJECT MATTER EXPERTS (SME)....... 1

1-6 WAIVERS .................................................................................................. 2

1-7 RELATED CRITERIA................................................................................. 2

1-8 POLICY...................................................................................................... 2

1-9 REFERENCED STANDARDS................................................................... 2

1-10 PROJECTS OUTSIDE OF CONTINENTAL UNITED STATES ................. 3

1-10.1 NATO Standards ....................................................................................... 3

1-10.2 Non-NATO Projects ................................................................................... 3

CHAPTER 2 - GENERAL DESIGN INFORMATION ....................................................... 4

2-1 OPERATIONAL CAPABILITIES ................................................................ 4

2-2 FUEL SPECIFICATIONS........................................................................... 4

2-3 FUEL PROPERTIES AND ADDITIVES..................................................... 5

2-3.1 Motor Gasoline (Mogas) [F-46] [ASTM D4814] .......................................... 5

2-3.2 Aviation Gasoline (Avgas) [F-18] [ASTM D910] ......................................... 5

2-3.3 Aviation Turbine Fuels ............................................................................... 5

2-3.4 Kerosene [ASTM D3699] ........................................................................... 6

2-3.5 Diesel Fuels ............................................................................................... 7

2-3.6 Burner Fuel Oils......................................................................................... 8

2-3.7 Alternative Fuel (E85) [ASTM D5798]........................................................ 9

2-3.8 Alternative Fuel Bio-Diesel (B20)............................................................... 9

2-3.9 Liquefied Petroleum Gas (LPG)............................................................... 10

2-3.10 Compressed Natural Gas (CNG)............................................................. 11

2-3.11 OTTO Fuels ............................................................................................. 12

2-3.12 Lubricating Oils ........................................................................................ 12

2-3.13 Hydrazine - Water (H-70) [MIL-PRF-26536] ............................................ 12

2-3.14 Fuel Additives .......................................................................................... 13

2-4 PRODUCT SEGREGATION.................................................................... 14

2-4.1 Product Grades........................................................................................ 14

2-4.2 Exceptions ............................................................................................... 14

2-5 TRANSFER FLOW RATES ..................................................................... 14

2-6 PHYSICAL SECURITY............................................................................ 16

2-6.1 Antiterrorism and Physical Security ......................................................... 16

2-6.2 Security Fencing ...................................................................................... 16

2-7 MAINTAINABILITY CAPABILITIES ......................................................... 16

2-8 VOICE COMMUNICATIONS ................................................................... 17

2-9 OTHER COMMUNICATIONS.................................................................. 17

2-9.1 Data Communications.............................................................................. 17

2-9.2 Fire Alarm Communication ...................................................................... 17

2-10 VAPOR RECOVERY............................................................................... 17

2-11 WORKER SAFETY.................................................................................. 17
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2-11.1 Safety Showers and Eyewash Fountains................................................. 17

2-12 ELECTRICAL DESIGN............................................................................ 18

2-12.1 Area Classifications ................................................................................. 18

2-12.2 Illumination............................................................................................... 20

2-12.3 Grounding and Bonding........................................................................... 20

2-13 CATHODIC PROTECTION...................................................................... 22

2-13.1 Tanks....................................................................................................... 22

2-13.2 Piping....................................................................................................... 22

2-13.3 Structures ................................................................................................ 23

2-14 ENVIRONMENTAL PROTECTION ......................................................... 23

2-14.1 General Policy ......................................................................................... 23

2-14.2 Regulations.............................................................................................. 23

2-14.3 Transfer of Fuel at Ports .......................................................................... 24

2-14.4 Air Quality Control.................................................................................... 25

2-14.5 Water Quality Control............................................................................... 26

2-14.6 Aboveground Storage Tanks ................................................................... 28

2-14.7 Underground Storage Tanks.................................................................... 29

2-15 FIRE PROTECTION ................................................................................ 29

2-15.1 General Requirements............................................................................. 29

2-15.2 Protection of Aboveground Storage Tanks .............................................. 29

2-15.3 Fire Protection of Pumping Facilities ....................................................... 30

2-15.4 Fire Protection of Underground Vertical Storage Tanks .......................... 30

2-15.5 Protection of Tank Truck and Tank Car Facilities .................................... 31

2-15.6 Protection of Aircraft Fueling Facilities..................................................... 31

2-15.7 Protection of Fuel Testing Laboratory...................................................... 31

2-15.8 Protection of Support Facilities ................................................................ 31

2-15.9 Protection of Fuel Piers............................................................................ 31

2-16 EMERGENCY SHUT-DOWN .................................................................. 31

2-17 ELECTROMAGNETIC RADIATION HAZARDS ...................................... 32

2-18 IDENTIFICATION .................................................................................... 32

2-19 ANTISTATIC DESIGN ............................................................................. 32

2-19.1 Piping Inlet Connections .......................................................................... 32

2-19.2 Enclosed Vapor Spaces........................................................................... 32

2-19.3 Filter/Separators ...................................................................................... 33

2-19.4 Aircraft Direct Fueling Stations ................................................................ 33

2-19.5 Truck Bottom Loading.............................................................................. 33

2-20 OPERATION AND MAINTENANCE DOCUMENTATION........................ 33

2-20.1 Equipment Operation and Maintenance Documentation ......................... 33

2-20.2 Operation and Maintenance Support Information (OMSI)........................ 33

2-21 PROTECTION AGAINST SEISMIC ACTIVITY........................................ 33

2-22 STRUCTURAL DESIGN.......................................................................... 34

2-23 CONCRETE............................................................................................. 34

2-24 AIRFIELD/AIRSPACE REQUIREMENTS................................................ 34

2-25 PERMITS................................................................................................. 34

CHAPTER 3 - BULK FUEL STORAGE FACILITIES..................................................... 35

3-1 INTRODUCTION ..................................................................................... 35

3-2 GENERAL REQUIREMENTS.................................................................. 35
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3-3 RECEIVING FACILITIES......................................................................... 35

3-3.1 Pipeline Receiving Facilities .................................................................... 35

3-3.2 Tank Truck and Tank Car Off-loading Facilities....................................... 37

3-3.3 Marine Off-loading Facilities .................................................................... 42

3-4 DISPENSING FACILITIES....................................................................... 43

3-4.1 Pipeline Pumping Facilities ...................................................................... 43

3-4.2 Tank Truck and Tank Car Loading Facilities............................................ 44

3-4.3 Marine Loading Facilities ......................................................................... 49

3-5 PIPING SYSTEMS .................................................................................. 49

3-5.1 Product Segregation ................................................................................ 49

3-6 EQUIPMENT DESCRIPTIONS................................................................ 50

3-6.1 Bulk Air Eliminators.................................................................................. 50

3-6.2 Meters...................................................................................................... 50

3-6.3 Pressure or Pressure/Vacuum Gauges ................................................... 51

3-6.4 Strainers .................................................................................................. 51

3-6.5 Surge Suppressors .................................................................................. 52

3-6.6 Pumps...................................................................................................... 52

3-6.7 Valves...................................................................................................... 53

3-6.8 Other Valves (Except Diaphragm Control Valves)................................... 57

3-6.9 Diaphragm Control Valves ....................................................................... 57

3-6.10 Thermometers ......................................................................................... 58

3-6.11 Fuel Hoses............................................................................................... 59

3-7 CONTROLS............................................................................................. 59

3-7.1 Design Requirements .............................................................................. 59

3-7.2 Flow Controls........................................................................................... 59

3-7.3 Pump Controls ......................................................................................... 59

3-8 CANOPIES .............................................................................................. 61

3-8.1 Canopies to Protect Fixed Assets............................................................ 61

3-8.2 Canopies to Reduce Stormwater............................................................. 62

3-9 PRODUCT RECOVERY SYSTEMS........................................................ 62

3-10 FUEL ADDITIVES.................................................................................... 62

CHAPTER 4 - AIRCRAFT FUELING FACILITIES......................................................... 63

4-1 INTRODUCTION ..................................................................................... 63

4-1.1 Function................................................................................................... 63

4-1.2 Aviation Turbine Fuels ............................................................................. 63

4-1.3 Special Precautions for Aviation Turbine Fuel Quality ............................. 63

4-2 GENERAL REQUIREMENTS.................................................................. 64

4-3 RECEIVING FACILITIES......................................................................... 64

4-3.1 Pipeline Receiving Facilities .................................................................... 64

4-3.2 Tank Truck and Tank Car Off-Loading Facilities...................................... 66

4-3.3 Marine Off-Loading Facilities ................................................................... 71

4-3.4 Special In-Bound Filtration....................................................................... 71

4-4 DISPENSING FACILITIES....................................................................... 71

4-4.1 Refueler Truck Fillstands ......................................................................... 71

4-4.2 Aircraft Direct Fueling Systems................................................................ 77

4-4.3 Marine Loading Facilities ......................................................................... 81

4-5 PIPING SYSTEMS .................................................................................. 81
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4-5.1 Product Segregation ................................................................................ 81

4-6 EQUIPMENT DESCRIPTIONS................................................................ 82

4-6.1 Bulk Air Eliminators.................................................................................. 82

4-6.2 Meters...................................................................................................... 82

4-6.3 Pressure or Pressure/Vacuum Gauges ................................................... 83

4-6.4 Strainers .................................................................................................. 83

4-6.5 Surge Suppressors .................................................................................. 84

4-6.6 Filter/Separators ...................................................................................... 84

4-6.7 Pumps...................................................................................................... 86

4-6.8 Valves...................................................................................................... 87

4-6.9 Other Valves (Except Diaphragm Control Valves)................................... 90

4-6.10 Diaphragm Control Valves ....................................................................... 91

4-6.11 Fuel Hoses............................................................................................... 92

4-7 CONTROLS............................................................................................. 92

4-7.1 Design Requirements .............................................................................. 92

4-7.2 Flow Controls........................................................................................... 93

4-7.3 Pump Controls ......................................................................................... 93

4-8 CANOPIES .............................................................................................. 95

4-8.1 Canopies to Protect Fixed Assets............................................................ 95

4-8.2 Canopies to Reduce Stormwater............................................................. 95

4-9 FUEL ADDITIVES.................................................................................... 95

4-9.1 Plus 100 Additive ..................................................................................... 95

4-10 DEFUELING AND RETURN-TO-BULK (RTB) SYSTEMS....................... 95

4-10.1 General Criteria ....................................................................................... 95

4-10.2 JP-5 Systems........................................................................................... 96

4-10.3 JP-8 Systems........................................................................................... 96

4-11 PRODUCT RECOVERY SYSTEMS........................................................ 97

4-11.1 Tank Trucks and Fuel Bowsers ............................................................... 97

4-11.2 Return to Bulk .......................................................................................... 97

CHAPTER 5 - MARINE RECEIVING AND DISPENSING FACILITIES....................... 100

5-1 FUNCTION ............................................................................................ 100

5-2 FUEL PIERS AND WHARVES .............................................................. 100

5-3 BERTHING PIERS ................................................................................ 100

5-4 OFFSHORE MOORINGS...................................................................... 100

5-5 GENERAL REQUIREMENTS................................................................ 100

5-6 GENERAL LAYOUT .............................................................................. 100

5-7 PIPING SYSTEMS ................................................................................ 101

5-7.1 Piping Arrangement ............................................................................... 101

5-8 EQUIPMENT DESCRIPTIONS.............................................................. 102

5-8.1 Loading/Off-Loading Arms..................................................................... 102

5-8.2 Fuel Hoses............................................................................................. 102

5-8.3 Submarine Fuel Hoses .......................................................................... 102

5-8.4 Meters.................................................................................................... 103

5-8.5 Strainers ................................................................................................ 103

5-8.6 Surge Suppressors ................................................................................ 104

5-8.7 Valves.................................................................................................... 104

5-8.8 Other Valves .......................................................................................... 107
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5-8.9 Pressure or Pressure/Vacuum Gauges ................................................. 107

5-8.10 Stripper Pumps ...................................................................................... 108

5-8.11 Excess Flow Sensors............................................................................. 108

5-8.12 Solid Cyclonic Separators...................................................................... 108

5-8.13 Grounding Systems ............................................................................... 108

5-8.14 Special Considerations for AviationTurbine Fuels ................................. 108

5-9 PRODUCT RECOVERY SYSTEMS...................................................... 108

5-10 WEATHER SHEDS................................................................................ 109

5-11 CANOPIES ............................................................................................ 109

5-12 SPECIAL CALCULATIONS ................................................................... 109

5-13 SAFETY SHOWERS AND EYEWASH FOUNTAINS ............................ 109

5-14 TRAFFIC BOLLARDS............................................................................ 109

5-15 SPECIAL DRAINAGE FOR FUELING PIERS ....................................... 109

5-16 BALLAST TREATMENT AND SLUDGE REMOVAL ............................. 110

5-16.1 Ballast Receiving and Treatment Facilities ............................................ 110

5-17 SLUDGE REMOVAL SYSTEMS ........................................................... 112

5-17.1 Design Requirements ............................................................................ 112

5-17.2 Sludge Disposal..................................................................................... 112

5-17.3 Piping Materials ..................................................................................... 112

CHAPTER 6 - INTERTERMINAL AND INSTALLATION PIPELINES.......................... 113

6-1 INTRODUCTION ................................................................................... 113

6-2 GENERAL REQUIREMENTS................................................................ 113

6-3 DESIGN REQUIREMENTS ................................................................... 113

6-3.1 Fuel Segregation ................................................................................... 113

6-3.2 Applicable Regulations .......................................................................... 113

6-3.3 Sampling................................................................................................ 113

6-3.4 Pigging................................................................................................... 114

6-3.5 Surge Suppression ................................................................................ 114

6-4 PIPING SYSTEMS ................................................................................ 114

6-5 EQUIPMENT ......................................................................................... 114

6-5.1 Meters.................................................................................................... 114

6-5.2 Manual Valves ....................................................................................... 114

6-5.3 Other Valves (Except Diaphragm Control Valves)................................. 117

6-5.4 Diaphragm Control Valves ..................................................................... 118

6-5.5 Strainers ................................................................................................ 119

6-5.6 Surge Suppressors ................................................................................ 120

6-5.7 Pigging Equipment................................................................................. 120

6-5.8 Pumps.................................................................................................... 120

6-5.9 Sampling Connections........................................................................... 120

6-5.10 Special Consideration for AviationTurbine Fuels ................................... 120

6-6 PRODUCT RECOVERY SYSTEMS...................................................... 121

6-7 CANOPIES ............................................................................................ 121

6-7.1 Canopies to Protect Fixed Assets.......................................................... 121

6-7.2 Canopies to Reduce Stormwater........................................................... 121

6-8 SPECIAL CALCULATIONS ................................................................... 121

CHAPTER 7 - GROUND PRODUCTS FUELING FACILITIES ................................... 122

7-1 INTRODUCTION ................................................................................... 122
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7-1.1 Types of Facilities .................................................................................. 122

7-2 GENERAL REQUIREMENTS................................................................ 122

7-3 DESIGN REQUIREMENTS ................................................................... 122

7-3.1 Fuel Segregation ................................................................................... 122

7-3.2 Facility Size............................................................................................ 122

7-3.3 Facility Configurations............................................................................ 123

7-3.4 Shelters.................................................................................................. 123

7-3.5 Concrete Fueling Area – Filling Stations................................................ 123

7-3.6 Concrete Fueling Area – Tactical Refueler Truck Loading Facilities...... 123

7-3.7 Canopies................................................................................................ 123

7-3.8 Regulations............................................................................................ 124

7-3.9 Bottom Loading...................................................................................... 124

7-4 STORAGE TANKS ................................................................................ 124

7-5 PIPING SYSTEMS ................................................................................ 124

7-5.1 Piping System – Tactical Refueler Facilities .......................................... 124

7-5.2 Aboveground Piping System – Filling Stations ...................................... 124

7-6 EQUIPMENT DESCRIPTIONS.............................................................. 124

7-6.1 Filling Stations ....................................................................................... 124

7-6.2 Tactical Refueler Truck Loading Facilities ............................................. 125

7-6.3 Valves.................................................................................................... 125

7-6.4 Diaphragm Control Valves ..................................................................... 126

7-6.5 Other Valves .......................................................................................... 126

7-7 VAPOR RECOVERY............................................................................. 127

CHAPTER 8 - ATMOSPHERIC STORAGE TANKS ................................................... 128

8-1 INTRODUCTION ................................................................................... 128

8-2 GENERAL REQUIREMENTS................................................................ 128

8-3 GENERAL CRITERIA............................................................................ 128

8-3.1 Materials ................................................................................................ 128

8-3.2 Protection............................................................................................... 128

8-3.3 Design Requirements ............................................................................ 128

8-3.4 Storage Capacity ................................................................................... 128

8-3.5 Tank Spacing......................................................................................... 129

8-3.6 Distance from Buildings and Property Lines .......................................... 130

8-3.7 Distance from Roadway, Railroads and Power Lines ............................ 131

8-3.8 Distance from Tank Truck and Tank Car Off-Loading and Loading....... 132

8-3.9 Interior Coatings .................................................................................... 132

8-3.10 Exterior Coatings ................................................................................... 132

8-3.11 Fill Piping ............................................................................................... 133

8-3.12 Vapor Emission Control Systems .......................................................... 133

8-3.13 Strapping Tables.................................................................................... 133

8-3.14 Product Recovery Systems.................................................................... 133

8-3.15 Registration............................................................................................ 134

8-4 HORIZONTAL ABOVEGROUND TANKS (SINGLE-WALL STEEL)...... 134

8-4.1 General Design Considerations ............................................................. 134

8-4.2 Installation.............................................................................................. 134

8-5 HORIZONTAL ABOVEGROUND TANKS (DOUBLE-WALL STEEL) .... 135

8-5.1 General Design Considerations ............................................................. 135
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8-5.2 Installation.............................................................................................. 135

8-6 HORIZONTAL ABOVEGROUND TANKS (FIRE-RESISTANT)............. 136

8-6.1 General Design Considerations ............................................................. 136

8-6.2 Installation.............................................................................................. 136

8-7 HORIZONTAL ABOVEGROUND TANKS (PROTECTED TANKS) ....... 137

8-7.1 General Design Considerations ............................................................. 137

8-7.2 Installation.............................................................................................. 137

8-8 ABOVEGROUND VERTICAL STORAGE TANKS................................. 138

8-8.1 General Design Considerations ............................................................. 138

8-8.2 Tank Roofs ............................................................................................ 139

8-8.3 Internal Floating Pans............................................................................ 139

8-8.4 Tank Bottoms......................................................................................... 140

8-8.5 Foundations ........................................................................................... 140

8-9 UNDERGROUND HORIZONTAL STORAGE TANKS........................... 141

8-9.1 General Design Considerations ............................................................. 141

8-9.2 Installation.............................................................................................. 142

8-10 UNDERGROUND VERTICAL STORAGE TANKS (Cut and Cover)...... 142

8-10.1 General Design Considerations ............................................................. 142

8-11 APPURTENANCES............................................................................... 143

8-12 HEATERS.............................................................................................. 143

8-12.1 General Design Considerations ............................................................. 143

8-12.2 Heating Medium..................................................................................... 143

8-12.3 Convection-Type.................................................................................... 143

8-12.4 In-Line Type........................................................................................... 143

8-12.5 Insulation and Tracing............................................................................ 144

8-13 UNDERGROUND STORAGE TANK SPILL CONTAINMENT 

SYSTEMS.............................................................................................. 144

8-13.1 General Design Considerations ............................................................. 144

8-14 ABOVEGROUND TANK SPILL CONTAINMENT SYSTEMS................ 144

8-14.1 General Design Considerations ............................................................. 144

8-14.2 Spill Containment System Capacity....................................................... 145

8-14.3 Remote Containment/Impoundment Spill Collection Systems............... 145

8-14.4 Diked Enclosure – Earthen Dike Type ................................................... 146

8-14.5 Diked Enclosure – Reinforced Concrete Dike Type............................... 146

8-14.6 Diked Enclosure – Combination Dike Type............................................ 146

8-14.7 Stormwater Collection Systems ............................................................. 146

8-14.8 Dike Access ........................................................................................... 146

8-15 MISCELLANEOUS USE TANKS........................................................... 147

8-15.1 Installation.............................................................................................. 147

8-15.2 Heating Oil Tanks .................................................................................. 147

8-15.3 Emergency Generator Fuel Tanks......................................................... 147

8-15.4 Fire Pump Fuel Tanks............................................................................ 147

8-15.5 Waste Oil Tanks .................................................................................... 147

8-15.6 Containment .......................................................................................... 147

8-15.7 Underground Tanks ............................................................................... 147

8-16 SHIPBOARD OFF-LOAD FUEL STORAGE TANKS............................. 148

8-16.1 Function................................................................................................. 148
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8-16.2 General Design Considerations ............................................................. 148

8-16.3 Locations ............................................................................................... 148

8-17 JET ENGINE TEST CELL FUEL STORAGE TANKS............................ 148

8-18 FUELS AUTOMATED SYSTEM............................................................ 148

CHAPTER 9 - PIPING SYSTEMS............................................................................... 154

9-1 INTRODUCTION ................................................................................... 154

9-2 GENERAL REQUIREMENTS................................................................ 154

9-2.1 Design Requirements ............................................................................ 154

9-2.2 Piping Arrangement ............................................................................... 156

9-2.3 Surge Analysis....................................................................................... 157

9-3 ABOVEGROUND PIPING ..................................................................... 158

9-3.1 Identification........................................................................................... 159

9-3.2 Pipe Supports ........................................................................................ 159

9-3.3 Arrangement.......................................................................................... 159

9-3.4 Anchors.................................................................................................. 159

9-3.5 Thermal Relief Valves............................................................................ 160

9-4 UNDERGROUND PIPING..................................................................... 160

9-4.1 Depth of Cover....................................................................................... 161

9-4.2 Parallel and Crossing Pipes................................................................... 161

9-4.3 Casing Sleeves...................................................................................... 161

9-4.4 Line Markers .......................................................................................... 162

9-4.5 Warning Tapes ...................................................................................... 162

9-4.6 Double-Wall Piping ................................................................................ 162

9-4.7 Single-Wall Piping Leak Detection Systems .......................................... 162

9-5 UNDERWATER PIPING........................................................................ 162

9-5.1 Special Arrangements............................................................................ 163

9-5.2 Connections........................................................................................... 163

9-5.3 Unique Considerations........................................................................... 163

9-5.4 Corrosion Protection .............................................................................. 163

9-5.5 Depth of Burial....................................................................................... 163

9-5.6 Pipe Thickness and Weight ................................................................... 164

9-6 PIPING MATERIALS ............................................................................. 164

9-6.1 Non-Aviation Systems............................................................................ 164

9-6.2 Aviation Systems ................................................................................... 164

9-7 WELDING CRITERIA ............................................................................ 164

9-8 PIPING CONNECTIONS ....................................................................... 164

9-9 INTERIOR PIPE COATINGS................................................................. 165

9-10 EXTERIOR PIPE COATINGS................................................................ 166

9-11 SAMPLING FACILITIES ........................................................................ 166

CHAPTER 10 - ALTERNATE POL FACILITIES.......................................................... 167

10-1 INTRODUCTION ................................................................................... 167

10-2 LIQUEFIED PETROLEUM GAS (LPG).................................................. 167

10-2.1 Uses....................................................................................................... 167

10-2.2 General Design Considerations ............................................................. 167

10-2.3 Receiving Facilities ................................................................................ 169

10-2.4 Storage Facilities ................................................................................... 170

10-2.5 Distribution Facilities.............................................................................. 172
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10-2.6 Air Mixing Facilities ................................................................................ 175

10-3 COMPRESSED NATURAL GAS (CNG)................................................ 175

10-3.1 Uses....................................................................................................... 175

10-3.2 General Design Considerations ............................................................. 176

10-3.3 Warning ................................................................................................. 178

10-4 HYDRAZINE STORAGE AND SERVICING FACILITIES ...................... 179

10-4.1 Uses....................................................................................................... 179

10-4.2 General Design Considerations ............................................................. 179

10-4.3 Construction Concepts........................................................................... 180

10-5 OTTO FUELS ........................................................................................ 184

CHAPTER 11 - SUPPORT FACILITIES...................................................................... 185

11-1 INTRODUCTION ................................................................................... 185

11-2 OPERATIONS BUILDING ..................................................................... 185

11-2.1 Design Standards .................................................................................. 185

11-2.2 Fuel Office ............................................................................................. 185

11-2.3 Training/Conference Room.................................................................... 185

11-2.4 Fuel Maintenance Workshop ................................................................. 185

11-2.5 Storeroom.............................................................................................. 185

11-2.6 Laboratory.............................................................................................. 185

11-2.7 Miscellaneous Safety Equipment........................................................... 187

11-2.8 Control Room......................................................................................... 187

11-2.9 Miscellaneous Spaces ........................................................................... 187

11-2.10 Communications .................................................................................... 187

11-3 ROADS.................................................................................................. 187

11-4 UTILITIES.............................................................................................. 187

11-5 AIRCRAFT REFUELER AND FUEL DELIVERY VEHICLE PARKING .. 188

11-5.1 General.................................................................................................. 188

11-5.2 Clearances............................................................................................. 188

11-5.3 Arrangement.......................................................................................... 189

11-5.4 Ingress/Egress....................................................................................... 189

11-5.5 Paving.................................................................................................... 189

11-5.6 Containment Area.................................................................................. 190

11-5.7 Remote Spill Containment System ........................................................ 190

11-5.8 Fire Protection ....................................................................................... 190

11-5.9 Security.................................................................................................. 190

11-5.10 Lighting .................................................................................................. 190

11-5.11 Block Heater Connections ..................................................................... 190

CHAPTER 12 - MAJOR REHABILITATION................................................................ 191

12-1 INTRODUCTION ................................................................................... 191

12-2 GENERAL REQUIREMENTS................................................................ 191

12-3 ABOVEGROUND FUEL STORAGE TANK REHABILITATION............. 191

12-3.1 Aboveground Vertical Tank Inspections................................................. 191

12-3.2 Increase Manhole Sizes......................................................................... 191

12-3.3 Replace Tank Floors.............................................................................. 192

12-3.4 Replace Floating Roof Tanks With Fixed Roofs .................................... 193

12-3.5 Product Recovery Systems.................................................................... 193

12-3.6 Coatings................................................................................................. 194
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12-3.7 Isolation Valves...................................................................................... 194

12-3.8 Alarms and High Level Shut-off Valves.................................................. 194

12-4 UNDERGROUND OPERATING TANKS ............................................... 194

12-4.1 Manholes ............................................................................................... 194

12-4.2 Interior Coatings .................................................................................... 194

12-5 HYDRANT SYSTEMS ........................................................................... 194

12-5.1 Pumps.................................................................................................... 195

12-5.2 Filter/Separators .................................................................................... 195

12-5.3 Fuel Quality Monitors............................................................................. 195

12-5.4 Control Systems .................................................................................... 195

12-5.5 Electrical Systems ................................................................................. 196

12-5.6 Lateral Control Pits ................................................................................ 196

12-5.7 Distribution Piping.................................................................................. 196

12-5.8 Diaphragm Control Valves ..................................................................... 196

12-5.9 Hydrant Outlets...................................................................................... 197

12-6 DIKES, LINERS, AND BASINS ............................................................. 197

12-7 LEAK DETECTION................................................................................ 197

12-8 CATHODIC PROTECTION.................................................................... 197

12-9 ISOLATION VALVES............................................................................. 197

12-10 SOIL AND GROUNDWATER REMEDIATION ...................................... 197

12-11 LIQUEFIED PETROLEUM GAS (LPG) FACILITIES ............................. 198

12-12 PIPELINE INSPECTION........................................................................ 198

12-12.1 Inspection .............................................................................................. 198

12-12.2 Smart Pigging ........................................................................................ 198

12-13 CHECKLIST........................................................................................... 198

CHAPTER 13 - FUELING FACILITY TEMPORARY DEACTIVATION........................ 202

13-1 INTRODUCTION ................................................................................... 202

13-2 GENERAL REQUIREMENTS................................................................ 202

13-3 FUEL STORAGE AND DISTRIBUTION FACILITIES ............................ 202

13-3.1 Tanks..................................................................................................... 202

13-3.2 Pipelines ................................................................................................ 204

13-4 FACILITIES............................................................................................ 205

13-4.1 General Considerations ......................................................................... 205

13-4.2 Fencing.................................................................................................. 205

13-4.3 Paved Surfaces ..................................................................................... 205

CHAPTER 14 - FUELING FACILITY CLOSURE ........................................................ 207

14-1 CLOSURE REQUIREMENTS................................................................ 207

14-1.1 Aboveground Tanks............................................................................... 207

14-1.2 Underground Tanks ............................................................................... 207

14-1.3 Pipelines ................................................................................................ 207

14-2 GENERAL REQUIREMENTS................................................................ 208

14-3 INVENTORY.......................................................................................... 208

GLOSSARY ................................................................................................................ 239

APPENDIX A - REFERENCES.................................................................................... A-1

APPENDIX B - MANUAL SURGE CALCULATIONS FOR SIMPLE PIPING 

SYSTEMS............................................................................................... B-1

APPENDIX C - CHARTER OF DoD FUELS FACILITY ENGINEERING PANEL ........ C-1
UFC 3-460-01

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TABLES

Table 2-1. Properties of Aviation Fuels .......................................................................... 6

Table 2-2. Physical Properties of Diesel Fuels............................................................... 7

Table 2-3. Physical Properties of Burner Fuel Oils......................................................... 8

Table 2-4. Design Flow Rates ...................................................................................... 15

Table 4-1. Aviation Turbine Fuel Receipt Filtration Table (1) (3).................................. 98

Table 8-1. Appurtenances .......................................................................................... 149

Table 9-1. Allowable Pressure Table – ANSI Class 150 Flanged Joints .................... 158

FIGURES

Plate 001 – UFC Chapter Identification Plan............................................................... 209

Plate 002 – Tank Truck and Tank Car Receiving and Dispensing Facilities ............... 210

Plate 003 – Tank Truck and Tank Car Off-Loading Drop Tank System ...................... 211

Plate 004 – Tank Truck and Tank Car Packaged Off-Loading System ....................... 212

Plate 005 – Tank Truck and Tank Car Loading System and Direct Off-Loading 

System..................................................................................................... 213

Plate 006 – Refueler Truck Facilities Layout Plan....................................................... 214

Plate 007 – Refueler Truck Loading Systems ............................................................. 215

Plate 008 – Aircraft Direct Fueling Systems Large Frame Aircraft On-Apron Fueling 

Positions .................................................................................................. 216

Plate 009 – Aircraft Direct Fueling Systems Small Frame Aircraft Fueling Lane and 

Apron Edge.............................................................................................. 217

Plate 010 – Aircraft Direct Fueling Systems Small Frame Aircraft In-Shelter Fueling 

Positions .................................................................................................. 218

Plate 011 – GOV Vehicle Motive Fuel Filling Station Plan .......................................... 219

Plate 012 – Tactical Refueler Ground Product Truck Loading Facility Plan ................ 220

Plate 013 – Tactical Refueler Ground Product Truck Loading Systems...................... 221

Plate 014 – Level Alarm Setpoints Vertical Aboveground Tank with Floating Pan...... 222

Plate 015 – Level Alarm Setpoints Vertical Aboveground Tank without Floating Pan . 223

Plate 016 – Aboveground Vertical Storage Tanks Inlet Fill Connection ...................... 224

Plate 017 – Horizontal Underground Storage Tanks Inlet Fill Connection................... 225

Plate 018 – Horizontal Aboveground Storage Tanks Inlet Fill Connection .................. 226

Plate 019 – Earthen Dikes........................................................................................... 227

Plate 020 – Piping Systems Sliding Pipe Support ....................................................... 228

Plate 021 – Piping Systems Anchor Pipe Support ...................................................... 229

Plate 022 – Aviation System Piping Materials System Standards............................... 230

Plate 023 – Thermal Relief Piping Systems Integral Valve and Conventional............. 231

Plate 024 – Thermal Relief Piping Systems Equipment Pump House or Pads ........... 232

Plate 025 – Thermal Relief Piping Systems Tank Truck and Refueler Racks ............. 233

Plate 026 – Thermal Relief Piping Systems Storage Tanks........................................ 234

Plate 027 – Liquefied Petroleum Gas Facilities Small Volume Facility for Trucks and 

Cylinders.................................................................................................. 235

Plate 028 – Liquefied Petroleum Gas Facilities Large Volume Facility for Tank Cars and 

Water Vessels.......................................................................................... 236

Plate 029 – Liquefied Petroleum Gas Facilities Tank Spacing Requirements............. 237

Plate 030 – Liquefied Petroleum Gas FacilitiesTank Spacing Requirements.............. 238
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CHAPTER 1 - INTRODUCTION

1-1 SCOPE

This Unified Facilities Criteria, UFC 3-460-01, contains general criteria and standard 

procedures for the design and construction of military land-based facilities which 

receive, store, distribute, or dispense liquid fuels. It is also applicable to the handling of 

liquefied petroleum gases (LPG) and compressed natural gas (CNG). It provides 

guidance on the rehabilitation, deactivation, or closure of fueling facilities. Support 

facilities are also included. Facility Plate 001 provides assistance in identifying UFC 

chapter numbers for specific fueling components.

1-2 USE OF UFC

The guidance contained in this UFC is intended for use by facility planners, engineers, 

and architects for individual project planning and for preparing engineering and 

construction documentation. In addition, it is intended for use by operations and 

maintenance personnel as a guidance document for facility design, modifications, and 

improvements.

1-3 PURPOSE OF CRITERIA

These criteria, except Chapters 12, 13, and 14 of this UFC, are intended for new 

construction only and do not apply retroactively to facilities existing at the time this UFC 

was issued. However, these criteria, including Chapters 12, 13, and 14, are applicable 

when modernizing or expanding existing facilities if the improvements can be justified in 

terms of obsolescence, expanded operational requirements, safety, environmental 

compliance, or excessive maintenance costs.

1-4 DEPARTMENT OF DEFENSE (DoD) FUELS FACILITY ENGINEERING 

PANEL

This UFC was updated by the DoD Fuels Facility Engineering Panel. This group is an 

association of recognized petroleum, oils, and lubricants (POL) experts, primarily from 

the engineering community, to advise the Services on ways to provide safe, 

operationally effective and economic fueling systems. The panel will investigate, 

develop, and recommend standardization of facilities, equipment, and procedures for 

storage, distribution, and dispensing systems for aircraft, marine, and ground fuels. The 

panel will investigate the use of facility component parts on DoD installations and will 

serve as a pool of expertise to assist in resolving systemic POL facility problems. It will 

also serve as a forum to update members on new equipment, DoD or service-specific 

programs, and changes affecting the fuels maintenance/repair community. Refer to 

Appendix C, Charter for DoD Fuels Facility Engineering for more information.

1-5 SERVICE HEADQUARTERS SUBJECT MATTER EXPERTS (SME)

It is recognized that the policies, obligations, and responsibilities of the military branches 

may vary on some minor points. Therefore, consult the Subject Matter Expert at the

appropriate Service Headquarters for interpretation. For the purposes of interpretation 
UFC 3-460-01

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2 

of this UFC, the Subject Matter Expert at the appropriate Service Headquarters is 

defined as follows:

a) Army – Headquarters, U.S. Army Corps of Engineers, POL Facilities 

Proponent (CECW-CE)

b) Air Force – The Air Force Fuels Engineer (HQ AFCESA/CEOA) 

through the applicable Major Command (MAJCOM) Fuels Engineer

c) Navy/Marine Corps: NAVFAC POL Facility Subject Matter Expert 

(NFESC-OP232). 

d) Defense Energy Support Center (DESC) – DESC Facilities Engineer. 

Defense Energy Support Center (DESC-WI) 

1-6 WAIVERS

For specific interpretations or waivers, contact the appropriate Service Headquarters

Subject Matter Experts (SME) and refer to MIL-STD-3007 for the waiver process. 

Substantive deviations from this UFC must first be presented to the appropriate Service 

Headquarters SMEs, and then reviewed / approved by the DoD Fuels Facility 

Engineering Panel, preferably in a normal meeting, prior to being carried further in the 

waiver process. Where time does not permit, approval may be obtained by polling the 

voting members. The DoD Fuel Facility Engineering Panel consists of members from 

the above Service Headquarters SMEs. 

1-7 RELATED CRITERIA

Other sources for criteria related to petroleum fuel facilities are identified in Appendix A, 

References. Any reference noted is the latest edition unless otherwise stated.

UFC 1-200-01 General Building Requirements, provides applicability of model building 

codes and government-unique criteria for typical design disciplines and building 

systems, as well as for accessibility, antiterrorism, security, sustainability, and safety. 

Use this UFC in addition to UFC 1-200-01 and the UFCs and government criteria 

referenced therein.

1-8 POLICY 

Design petroleum fuel facilities to meet the operational and management requirements 

of the command in which the facility is located, as well as to meet all applicable federal, 

state, and local regulations concerning environmental, health, safety, and fire protection 

issues. 

1-9 REFERENCED STANDARDS

The execution agency issuing a contract for design and/or construction services will 

direct the use of standard designs, guide specifications, and/or definitive drawings. In 

other situations where these standards are not readily available, contact appropriate 

Service Headquarters for assistance in obtaining these documents.
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3 

1-10 PROJECTS OUTSIDE OF CONTINENTAL UNITED STATES

1-10.1 NATO Standards

For fueling projects outside of the continental United States (CONUS) and in a NATO 

(North Atlantic Treaty Organization) country, review and comply with all appropriate 

NATO documents.

1-10.2 Non-NATO Projects

For fueling projects located outside of the CONUS and not in a NATO country, use this 

UFC, applicable Service policy, and host-nation standards (if more stringent).
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4 

CHAPTER 2 - GENERAL DESIGN INFORMATION

2-1 OPERATIONAL CAPABILITIES

Design fuel facilities for continued operation using emergency or temporary expedients 

despite the loss of one or more components of the fuel receiving and/or dispensing 

system by enemy action or other factors. For tactical or mission-related fuel facilities, 

provide an alternative source of fuel supply to the fuel facility to ensure emergency 

operation under the most adverse conditions, including back-up power (emergency

generators). Maintain consistency with prescribed criteria in appropriate directives, 

instructions, and standard designs (including NATO Standards).

2-2 FUEL SPECIFICATIONS

The following specifications apply to the various petroleum fuels that may be addressed:

a) MIL-DTL-5624, Turbine Fuel, Aviation, Grades JP-4 and JP-5.

b) MIL-DTL-38219, Turbine Fuel, Low Volatility, JP-7.

c) MIL-DTL-83133, Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO 

F-34), and NATO F-35, and JP-8+100 (NATO F-37). 

d) MIL-DTL-25524, Turbine Fuel, Aviation, Thermally Stable.

e) ASTM D1655, Standard Specification for Aviation Turbine Fuels.

f) CID A-A-52557, Fuel Oil, Diesel; for Posts, Camps and Stations.

g) CID A-A-59693, Diesel Fuel, Biodiesel Blend (B20). 

h) MIL-DTL-16884, Fuel, Naval Distillate. 

i) ASTM D3699, Standard Specification for Kerosene. 

j) ASTM D4814, Standard Specification for Automotive Spark-Ignition 

Engine Fuel.

k) ASTM D910, Standard Specification for Aviation Gasoline (Avgas)

l) ASTM D975, Standard Specification for Diesel Fuel Oils. 

m) MIL-DTL-87107, Propellant, High Density Synthetic Hydrocarbon Type, 

Grade JP-10.

n) ASTM D5798, Standard Specification for Fuel Ethanol (Ed75-Ed85) for 

Automotive Spark-Ignition Engines. 

o) ASTM D6751, Standard Specification for Biodiesel Fuel Blend Stock 

(B100) for Middle Distillate Fuels. 
UFC 3-460-01

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5 

2-3 FUEL PROPERTIES AND ADDITIVES

In addition to the fuel specifications, refer to Coordinating Research Council, Inc. (CRC), 

Handbook of Aviation Fuel Properties, for additional fuel properties. The following 

paragraphs list typical physical properties of various grades of fuel and additives which 

would affect the design of a petroleum fuel facility. The NATO designation is shown in 

brackets.

2-3.1 Motor Gasoline (Mogas) [F-46] [ASTM D4814] 

2-3.1.1 Special Precautions for Mogas

Because of its high volatility, gasoline produces large amounts of vapor at ordinary 

temperatures. When confined in a tank or container at liquid temperatures above 20 

degrees F (-7 degrees C), the vapor space is normally too rich to be explosive. At 

temperatures 20 degrees F (-7 degrees C) or less, vapor spaces above gasoline may 

be in the explosive range. One gallon (3.785 L) of liquid gasoline when vaporized will 

occupy about 25 cubic feet of space (0.7 m3), and if permitted to escape and become 

diluted with air, it is highly flammable. Provide a design that precludes disposing of 

Mogas into storm or sanitary sewers.

2-3.2 Aviation Gasoline (Avgas) [F-18] [ASTM D910] 

2-3.2.1 Description of Aviation Gasoline

Aviation gasoline is a high-octane aviation fuel used for piston or Wankel engine 

powered aircraft. It is distinguished from motor gasoline, which is the everyday gasoline 

used in ground vehicles. In military service, avgas is seldom used in manned aircraft 

but is commonly used in Unmanned Aerial Vehicles (UAVs). 

2-3.2.2 Avgas Grades

100LL, spoken as "100 low lead", is the most common grade used in military 

applications. It is dyed blue, and contains a maximum of 2 grams of lead per US gallon

(0.56 grams/liter) and is the most commonly available and used aviation gasoline. 

Other grades that are theoretically available include Grade 80, Grade 91, Grade 100, 

and Grade 82UL. The differences between all 80, 91, 100, and 100LL are lead content 

and color. Grade 82UL is unleaded.

2-3.2.3 Special Precautions for Avgas

Using the wrong grade of gasoline will cause engine problems. Virtually all grades of 

avgas available contain tetra-ethyl lead (TEL) as a lead based anti-knock compound. 

See Mogas for flammability issues. 

2-3.3 Aviation Turbine Fuels

2-3.3.1 Physical Properties of Aviation Turbine Fuels
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Table 2-1. Properties of Aviation Fuels

Grade 

Number Property

Relative 

density

Specific 

Gravity

Reid Vapor 

Pressure at 

100°F(38°C)

psia (kPa)

Minimum 

Flash 

Point, 

°F (°C)

Average (kin.) 

Viscosity at 100°F 

(38°C), ft2

/s x 10-5 

(cSt)

Freezing 

Point,

°F (°C)

JP-4 [F-40] 57° to 45° 

API

0.751 to 

0.802

2 to 3 (13.8 to 

20.7) -20 (-29) 0.9 x 10-5 (0.8) -72 (-58)

JP-5 [F-44] 48° to 36°

API

0.788 to 

0.845 0.04 (0.3) 140 (60) 1.6 x 10-5 (1.5) -61 (-52)

JP-8 [F-34, 

F-37]

51° to 37° 

API

0.775 to 

0.840 0.05 (0.3) 100 (38) 1.9 x 10-5 (1.8) -53 (-47)

JP-10 20° to 

18.5° API

0.935 to 

0.943 0.11 (0.8) 67 (19) 3.4 x 10-5 (3.2) -110 (-79)

JPTS 53° to 46°

API

0.767 to

0.797 0.11 (0.8) 110 (43) 1.3 x 10-5 (1.2) -64 (-53)

Jet A 51° to 37° 

API

0.775 to 

0.840 0.029 (0.2) 100 (38) 1.6 x 10-5 (1.5) -40 (-40)

Jet A-1

[F-35]

51° to 37°

API

0.775 to 

0.840 0.05 (0.3) 100 (38) 1.6 x 10-5 (1.5) -53 (-47)

Hydrazine 9° API 1.007 NA 126 (52) NA NA

2-3.3.2 Special Precautions for Aviation Turbine Fuels

Because of the serious consequences of a turbine engine failure and the nature of the 

fuel systems in turbine engines, provide designs which include means to prevent 

Contamination of aviation turbine fuels by dirt, water, or other types of fuels. Solid 

contaminants are generally those which are insoluble in fuel. Most common are iron 

rust, scale, sand, and dirt. Iron rust contaminates aviation turbine fuel. Special filtration 

is required for receiving aviation turbine fuel into bulk storage and operating storage to 

remove contaminants before the fuel is delivered to aircraft. To preserve fuel quality, 

limit materials in contact with the fuel to stainless steel, non-ferrous, or coated carbon 

steel for aircraft fueling systems. Do not use zinc, copper, and zinc- or copper-bearing 

alloys in contact with aviation turbine fuels, including pipe, valves, equipment, and 

accessories. The maximum allowable aircraft servicing use limits of solids is 2.0 mg/L 

and the maximum allowable aircraft servicing use limits of free water is 5 ppm. Provide 

a design that precludes disposing of aviation turbine fuels into storm or sanitary sewers. 

2-3.4 Kerosene [ASTM D3699] 

2-3.4.1 Physical Properties of Kerosene

a) Relative density

API Gravity 51 degrees to 37 degrees API

Specific Gravity 0.775 to 0.840
UFC 3-460-01

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7 

b) Reid Vapor Pressure 0.5 psia (3.5 kPa) (maximum at 100 degrees F 

(38 degrees C))

c) Flash Point (minimum) 100 degrees F (38 degrees C)

d) Viscosity at 104 degrees F (40 degrees C) 1 to 2 x 10-5 ft2/s (0.9 to 1.9 

cSt.)

e) Freezing Point -22 degrees F (-30 degrees C) (maximum)

2-3.4.2 Special Precautions for Kerosene

Design separate systems for kerosene to avoid discoloration caused by contamination. 

Provide a design that precludes disposing of kerosene into storm or sanitary sewers.

2-3.5 Diesel Fuels

2-3.5.1 Sulfur Content of Diesel Fuels

Diesel fuel that is available for motive fuel in the United States is Low Sulfur Diesel 

(LSD) which has a maximum sulfur content of 500 ppm and Ultra Low Sulfur Diesel 

(ULSD) which has a maximum sulfur content of 15 ppm, both meeting ASTM D975. 

2-3.5.2 Physical Properties of Diesel Fuels

Table 2-2. Physical Properties of Diesel Fuels

Automotive DF-2 

[F-54]

Diesel Fuel Marine 

[F-76]

Ultra Low Sulfur 

Diesel [ASTM D975]

(a) Relative density API 

Gravity, °API (Specific 

Gravity)

40 to 34 (0.825 to 

0.855)

39 to 33 (0.830 to 

0.860) 30 (0.876) 

(b) Reid Vapor Pressure 

at 100 °F (38 °C), psia 

(kPa)

0 (0) 0 (0) 0 (0)

(c) Flash Point, °F (°C) 131 (55) 140 (60) 150 (66)

(d) Viscosity at 104°F 

(40°C) ft2/s (cSt)

2.0 to 4.4 x 10-5

(1.9 to 4.1)

1.8 to 4.6 x 10-5

(1.7 to 4.3)

2.7 x 10-5 (2.5)

(e) Pour Point, °F (°C) 10 (-12) 20 (-7) 0 (-18)

Notes: JP-8 is currently used as arctic grade diesel fuel (DFA) in the Arctic and Antarctic for heating 

fuel. The gross heating value of JP-8 is 18,400 Btu/lb (42 800 kJ/kg).

DF-1, winter grade diesel fuel, has a flash point of 100 degrees F (38 degrees C) and a 

viscosity of 1.4 to 2.6 x 10-5 ft2/s (1.3 to 2.4 cSt) at 104 degrees F (40 degrees C).

2-3.5.3 Special Precautions for Low Sulfur Diesel Fuels 

While not as critical as with aviation turbine fuels, diesel fuel systems are subject to 

damage by dirt and water in the fuel. Avoid contamination by dirt and water or dilution 

by lighter fuels. In cold climates, provide designs that will prevent “gelling.” Provide a 

design that precludes disposing of diesel fuels into storm or sanitary sewers.
UFC 3-460-01

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8 

2-3.5.4 Special Precautions for Ultra Low Sulfur Diesel

With the reduction in sulfur content comes a reduction in overall lubricity and 

conductivity of the fuel. A lower lubricity level can cause premature wear and damage 

to metal parts in typical compression ignition engines. Lubricity additives are added in 

accordance with ASTM D975 . Lower conductivity can cause a potential for an 

increased risk in fire or explosion caused by static electricity. Even though a 

conductivity additive is added it is recommended that flow rates are limited and bonding 

and grounding equipment be utilized to minimize static electricity during loading 

operations. 

2-3.6 Burner Fuel Oils

2-3.6.1 Physical Properties of Burner Fuel Oils

Table 2-3. Physical Properties of Burner Fuel Oils

Grade Number

1 2 4 5 Light 5 Heavy 6

Relative Density

°API

48 to 36 40 to 28 30 to 15 22 to 14 23 to 8 22 to 7

Specific Gravity 0.786 to 

0.843

0.825 to 

0.877

0.876 to 

0.966

0.922 to 

0.972

0.913 to 

1.017

0.922 to 

1.022

Reid Vapor 

Pressure at 100°F 

(38°C), psia (kPa)

< 0.1

(< 0.7)

< 0.1

(< 0.7)

< 0.1

(< 0.7)

< 0.1

(< 0.7)

< 0.1

(< 0.7)

< 0.1

(< 0.7)

Minimum Flash 

Point, °F (°C)

100 (38) 100 (38) 130 (54) 130 (54) 130 (54) 150 (66)

Average viscosity

at 100°F (38°C), 

ft2

/s x 10-5

(cSt)

1.5 to 2.4

(1.4 to 2.2)

2 to 3.3

(1.9 to 

3.1)

11.3 to 

70

(10.5 to 

65)

70 to 215

(65 to 200)

323 to 969

(300 to 900)

208 to 

807

(193 to 

750)

Pour Point,

°F (°C)

-10 (-23) -5 (-21) 21 (-6) 20 to 30

(-7 to -1)

20 to 30

(-7 to -1)

30 to 70

(-1 to 21)

Gross Heat Value,

Btu/lb (kJ/kg)

19,765

(45 973)

19,460

(45 264)

18,840

(43 820)

18,560

(43 171)

18,825

(43 787)

18,200

(42 333)

2-3.6.2 Special Precautions for Burner Fuel Oils

When the ambient temperature of the burner fuel oil is less than 20 degrees F (11 

degrees C) above the pour point temperature, the burner fuel oil needs to be heated. At 

the burner fuel oil’s pour point temperature, the fuel oil has reached a gel-like state and 

would be difficult to pump. In nearly all cases, No. 6 fuel oil requires heating to be 

pumped. In some cases, No. 4 and No. 5 burner fuel oils will require heating. Provide a 

design that precludes disposing of burner fuel oils into storm or sanitary sewers.
UFC 3-460-01

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9 

2-3.7 Alternative Fuel (E85) [ASTM D5798] 

2-3.7.1 Physical Properties of E85

a) Specific Gravity 0.760 to 0.780

b) Reid Vapor Pressure 6-12 psia (42 to 83 kPa)

c) Flash Point (minimum) -20 degrees F (-30 degrees C) 

d) Viscosity is 6.1x10-6 to 3.4x10-5 ft2/s (0.57 to 3.19 cSt)

e) Pour Point -212 degrees F (-100 degrees C)

2-3.7.2 Special Precautions for E85 

Due to the corrosiveness of E85, many common materials used with gasoline systems 

are not compatible with the handling and storage of alcohols (E85, or ethanol, is 85

percent ethyl alcohol). Zinc, brass, lead, aluminum, and lead based solder are several 

metals that become degraded by ethanol exposure. Other metals, including unplated 

steel, stainless steel, black iron and bronze seem to have acceptable resistance to 

ethanol corrosion. Certain nonmetallic materials that have been successfully used with 

ethanol include: Buna-N, Neoprene rubber, polyethylene, nylon, polypropylene, nitrile, 

Viton, and Teflon. Common nonmetallic materials degraded by ethanol are natural 

rubber, polyurethane, cork gasket material, leather, polyester-bonded fiberglass 

laminate, polyvinyl chloride (PVC), polyamides, and methyl-methacrylate plastics. 

Proper cleaning of existing tanks that are being converted for E85 storage is required, 

because E85’s solvent properties loosen tank deposits. In ethanol dispensing a onemicron in-line filter is recommended for impurity/particle removal. The shelf life of E85 

is approximately 60-90 days in some cases. At normal temperatures E85 is less 

explosive than gasoline, but E85 is more explosive at lower temperatures. Ethanol 

vapors have similar behavior to gasoline, but a lower vapor pressure. E85 is an 

electrical conductor, and is potentially carcinogenic. Provide a design that precludes 

disposing of E85 into storm or sanitary sewers. For Air Force projects see ETL 03-04. 

2-3.8 Alternative Fuel Bio-Diesel (B20)

2-3.8.1 Physical Properties of Bio-Diesel

Biodiesel fuel B20 is a blend of petroleum diesel fuel meeting ASTM D975 and 100

percent (neat) biodiesel fuel meeting either ASTM D6751 or EN 14214, where the 

biodiesel content of the blended fuel is no more than 20 percent biodiesel by volume 

(B20). Biodiesel has physical properties very similar to conventional diesel.

a) Specific Gravity 0.870 to 0.890

b) Reid Vapor Pressure 0.0 psia (0.0 kPa) (maximum at 100 degrees F 

(38 degrees C))
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c) Flash Point (minimum) 100 degrees F (38 degrees C) for D1, 126 

degrees F (52 degrees C)

d) Viscosity at 104 degrees F (40 degrees C) 1.2 to 4.4 x 10-5 ft2/s (1.3 to 

4.1 cSt.)

e) Pour Point 10 degrees F (-12 degrees C)

2-3.8.2 Special Precautions for Bio-Diesel

In dispensing Bio-Diesel, it is recommended that a 30-micron and a 10-micron in-line

filter be used, in succession, as a primary and secondary means for impurity/particle 

removal. Bio-Diesel (B100) has good solvent qualities and will remove deposits from 

fuel systems. As a result, it may require more filter changes initially. One of the most 

commonly used blends of Bio-Diesel is B20. B20 has not been approved for use in 

combat or tactical vehicles or equipment. The usage of bio-diesel in other 

engines/vehicles has been reviewed by vehicle manufacturers and copies can be 

obtained at http://www.biodiesel.org/. B20 should be used within six months of 

manufacturer, because of the fuels shelf life. Users should be aware that a B20 blend 

will have increased viscosity requirements. Provide a design that precludes disposing 

of bio-diesel fuels into storm or sanitary sewers. For Air Force projects see ETL 03-04. 

2-3.9 Liquefied Petroleum Gas (LPG)

2-3.9.1 Physical Properties of LPG

LPG is composed predominantly of propane and propylene with minor amounts of 

butane, isobutane, and butylene. It is odorless, colorless, and non-toxic. To reduce the 

danger of an explosion from undetected leaks, commercial LPG usually contains an 

odorizing agent which gives it a distinctive pungent odor. LPG is a vapor at 

atmospheric conditions. It is normally stored as a liquid at a storage pressure of 200 

psia (1400 kPa). LPG has the following properties:

a) Freezing Point, degrees F (degrees C) -305 (-187)

b) Relative Density (Specific Gravity) 147 degrees API (0.588)

c) Vapor Pressure at 100 degrees F (38 degrees C), 175.8 (1212) psi 

(kPa)

d) Heat Content, Btu/lb (kJ/kg) 21,591 (50 221)

2-3.9.2 Special Precautions for LPG

a) Store LPG under pressure in appropriate pressure-rated tanks.

b) The potential for fire and explosion presents extreme hazards to life 

and property. Provide adequate relief venting and additional fire 

protection in accordance with NFPA 58. 
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c) Provide tank spacing in accordance with the requirements of Chapter 

10 of this UFC.

2-3.10 Compressed Natural Gas (CNG)

2-3.10.1 Physical Properties of CNG

Appendix A to NFPA 52, Compressed Natural Gas (CNG) Vehicular Fuel Systems, 

defines certain CNG properties. Natural gas is a flammable gas. It is colorless, 

tasteless, and non-toxic. It is a light gas, weighing about two thirds as much as air. It 

tends to rise and diffuse rapidly in air when it escapes from the system. Natural gas 

burns in air with a luminous flame. At atmospheric pressure, the ignition temperature of 

natural gas mixtures has been reported to be as low as 900 degrees F (482 degrees C). 

The flammable limits of natural gas-air mixtures at atmospheric pressure are about 5 

percent to 15 percent by volume of natural gas. While natural gas consists principally of 

methane, it also contains ethane, small amounts of propane, butane, and higher 

Hydrocarbons and may contain small amounts of nitrogen, carbon dioxide, hydrogen 

sulfide, and helium which will vary from zero to a few percent depending upon the 

source and seasonal effects. As distributed in the United States and Canada, natural 

gas also contains water vapor. This “pipeline quality” gas can contain 7 pounds or more 

of water per million cubic feet of gas (112 kg/106 m3

). Some constituents of natural 

gas, especially carbon dioxide and hydrogen sulfide in the presence of liquid water, can 

be corrosive to carbon steel, and the corrosive effect is increased by pressure. The 

pressures used in CNG systems covered by NFPA 52 are substantial and well above 

those used in transmission and distribution piping and in other natural gas consuming 

equipment. As excessive corrosion can lead to sudden explosive rupture of a container, 

this hazard must be controlled. Pressures in CNG fueling stations are typically less 

than 5,000 psi (35 000 kPa).

2-3.10.2 Special Precautions for CNG

a) Provide venting for safety relief in areas where CNG is to be stored.

b) CNG is a highly flammable substance. Therefore, in design of 

facilities, use the following precautions to prevent fires from becoming 

uncontrollable:

(1) Do not directly extinguish fires with water.

(2) Do not extinguish large fires.

(3) Allow large fires to burn while cooling adjacent equipment with 

water spray.

(4) Shut-off CNG source, if possible.

(5) Extinguish small fires with dry chemicals.
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c) CNG is non-toxic but can cause anoxia (asphyxiation) when it 

displaces the normal 21 percent oxygen in a confined area without 

adequate ventilation.

d) Because of corrosion problems, water in Department of Transportation 

(DOT) certified tanks is limited to 0.5 pounds per million cubic feet (8 

kg/10 6 m3).

2-3.11 OTTO Fuels

Information on OTTO fuels is contained in NAVSEA S6340-AA-MMA-010, Technical 

Manual for OTTO Fuel II Safety, Storage, and Handling Instructions, published by 

direction of Commander, Naval Sea Systems Command. Distribution of this document 

is restricted and Naval Sea Systems Command handles requests for information. 

2-3.12 Lubricating Oils

2-3.12.1 Steam Turbine Lubricating Oils [0-250] [MIL-PRF-17331] 

a) For use in main turbines and gears, auxiliary turbine installations, 

certain hydraulic equipment, general mechanical lubrication, and air 

compressors.

b) Physical Properties:

(1) Flash Point: 400 degrees F (204 degrees C) minimum. 

(2) Pour Point: 20 degrees F (-6 degrees C) maximum. 

(3) Viscosity at 104 degrees F (40 degrees C), 80 to 104 x 10-5 ft2/s 

(74 to 97 x 10-6 m2

/s). 

2-3.12.2 Lubricating Oils [0-278], [MIL-PRF-9000] 

For use in advanced design high-output shipboard main propulsion and auxiliary diesel 

engines using fuel conforming to MIL-DTL-16884. 

2-3.12.3 Special Precautions for Lubricating Oils

To pump the oil when the ambient temperature of the lubricating oil is less than 20 

degrees F (11 degrees C) above the pour point temperature, heat the lubricating oil. At 

the pour point temperature, the oil becomes gel-like and is difficult to pump. Ensure the 

design does not allow the discharge of lubricating oil into storm or sanitary sewers.

2-3.13 Hydrazine - Water (H-70) [MIL-PRF-26536] 

2-3.13.1 Physical Properties of H-70

This fuel is a mixture of 70 percent hydrazine and 30 percent water. It is a clear, oily, 

water-like liquid with a fishy, ammonia-like odor. It is stable under extremes of heat and 

cold; however, it will react with carbon dioxide and oxygen in the air. It may ignite 

spontaneously when in contact with metallic oxides such as rust. 
UFC 3-460-01

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2-3.13.2 Special Precautions for H-70

Keep working and storage areas clean and free of materials that may react with 

hydrazine. Provide only stainless steel in areas where extended contact is possible. 

Areas where incidental contact is possible should be kept free of rust. Ensure the 

design does not allow the discharge of H-70 into storm or sanitary sewers.

2-3.14 Fuel Additives

2-3.14.1 Fuel System Icing Inhibitor (FSII), High Flash, [MIL-DTL-85470] 

(diethylene glycol monomethyl ether (DIEGME))

a) Used in aviation turbine fuels to prevent the formation of ice crystals 

from entrapped water in the fuel at freezing temperatures. In addition, 

it has good biocidal properties, preventing growth of microorganisms in 

the fuel.

b) Avoid water entry/bottoms in storage tanks because the additive will 

dissolve in the water, reducing the concentration of additives left in the 

fuel. 

c) Refer to fuel specification for more information.

d) Consult federal, state, and local regulations for appropriate disposal 

methods.

2-3.14.2 Corrosion Inhibitor/Lubricity Improver (CI), [MIL-PRF-25017] 

A combination lubricity improver and corrosion inhibitor additive, procured under 

MIL-PRF-25017, is injected in all military aviation turbine fuels at the refinery in order to 

improve the lubricating characteristics of the fuel.

2-3.14.3 Static Dissipater Additive

Static dissipater additive (SDA) enhances safety during handling and flight by reducing 

static discharge potential in the vapor space above the fuel. SDA increases the 

conductivity of the fuel, thus decreasing the electrostatic charge relaxation time (the rate 

of which a charge dissipates or travels through the fuel) which decreases the potential 

for ignition from static charges. The actual proportion is in accordance with the specific 

fuel military specification. For fuel system design purposes, assume a lower limit of 50 

picosiemens per meter in the determination of relaxation requirements. SDA is added 

to all JP-8 (F-34; F-35; F-37). SDA is not added to JP-5 and F-76 or to Jet A/A-1 that is 

stored at military installations.

2-3.14.4 Thermal Stability Improver Additive (+100 Additive)

Thermal stability additive (TSIA) enhances safety during handling and flight by 

increasing fuel tolerance to elevated temperatures. JP-8+100 (NATO F-37) is the 

aviation turbine fuel that utilizes TSIA.
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2-4 PRODUCT SEGREGATION

2-4.1 Product Grades

Except as otherwise approved by Service Headquarters, provide separate receiving, 

storage, and distribution systems for each product. Except as otherwise approved by 

Service Headquarters, prevent misfueling (transferring a type of fuel other than the type 

intended) by using different size piping, valves, adaptors, nozzles, etc. The products to 

be segregated include:

a) Mogas.

b) Diesel fuel, including ultra-low sulfur diesel and distillate type burner 

fuels (No. 1, No. 2, and kerosene).

c) Aviation turbine fuel, separate systems for each grade.

d) Residual type burner fuels (No. 4, No. 5, and No. 6).

e) LPG.

f) CNG.

g) OTTO fuels.

h) E85.

i) Bio-diesel.

2-4.2 Exceptions

Designs for different products using the same piping may be approved for long receiving 

lines such as from a tanker or barge pier or a cross-country pipeline to a storage facility. 

Where such common use occurs, make provisions for receiving and segregating the 

interface between two products. Consider the use of pigs or break-out tanks to 

separate batches. Exceptions will not be approved for common systems to carry both 

clean and residual type fuels.

2-5 TRANSFER FLOW RATES

Table 2-4 shows the recommended range of design flow rates. In some cases, greater 

rates may be needed to meet the operational requirements of a particular facility.
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Table 2-4. Design Flow Rates

Service1

Aviation 

Turbine 

Fuel

Diesel Fuel Burner Fuel 

Oils

Mogas

Between storage tanks, gpm 

(m3/hr)

600 to 1,200

(136 to 272)

600 to 1,200

(136 to 272)

600 to 1,200

(136 to 272)

600 to 1,200

(136 to 272)

Tank car unloading to 

storage (per car), gpm 

(m3/hr)

300 to 600

(68 to 136) 

300 to 600

(68 to 136) 

300 to 600

(68 to 136) 

300

(68) 

Tank truck unloading to 

storage (per truck), gpm 

(m3/hr)

300 to 600

(68 to 136) 

300 to 600

(68 to 136) 

300 to 600

(68 to 136) 

300 to 600

(68 to 136) 

Gravity receipt tank to 

storage gpm (m3/hr)

600

(136)

600

(136)

600

(136)

600

(136)

Storage to tank truck/refueler 

loading (per truck), gpm 

(m3/hr)

300 or 600

(68 or 136) 

300 or 600

(68 or 136) 

300 or 600

(68 or 136) 

300 or 600

(68 or 136) 

Delivery from direct fueling 

stations to aircraft, gpm 

(m3/hr)

Varies2 N/A N/A N/A

Delivery from direct fueling 

stations to helicopters,

gpm (m3/hr)

Varies2 N/A N/A N/A

Between super tanker and 

storage, gpm (m3/hr)

16,800

(3815)

16,800

(3815)

16,800

(3815)

16,800

(3815)

Between regular tanker and 

storage, gpm (m3/hr)

7,000

(1590)

7,000

(1590)

7,000

(1590)

7,000

(1590)

Between barge and storage, 

gpm (m3/hr)

2,800

(636)

2,800

(636)

2,800

(636)

2,800

(636)

To fleet oilers, gpm (m3/hr) 3,500

(795)

3,500

(795) N/A N/A

To AOEs, gpm (m3/hr) 7,000

(1590)

7,000

(1590) N/A N/A

To carriers, gpm (m3/hr) 2,450

(556)

2,450

(556) N/A N/A

To average cruisers, gpm 

(m3/hr)

700

(159)

1,400

(318) N/A N/A

To average destroyers,

gpm (m3/hr)

700

(159)

1,400

(318) N/A N/A

Storage to tank car loading 

(per car), gpm (m3/hr)

300 or 600

(68 or 136)

300 or 600

(68 or 136)

300 or 600

(68 or 136)

300 or 600

(68 or 136)

1

At dockside, deliveries from tankers should be assumed to be at a pressure of 80 to 100 psig 

(600 to 700 kPa), and deliveries to tankers to be at 60 psig (400 kPa). Rates to other ships are 

maximums based on fueling at sea capacities. Lesser rates for fueling at piers can be used if more 

practical. Loading rates are based on 40 psig (300 kPa) maximum per hose at ship connections.

2 Refer to Chapter 4 of this UFC for guidance on fueling rates for aircraft. Contact appropriate 

Service Headquarters for actual fueling rates for aircraft for which design applies.
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2-6 PHYSICAL SECURITY

Plan and design fuel facilities with the goal of protecting the fuels, storage, and transfer 

capability from enemy attack, terrorists, sabotage, fire, seismic activity, and other 

damaging influences. In high threat areas, more extensive protection may be required. 

Consult appropriate Service Headquarters for guidance. NATO projects have their own 

specific criteria which govern protection level requirements.

2-6.1 Antiterrorism and Physical Security

Per DoD 5200.08-R, Physical Security Program, at a minimum, fuel support points, 

pipeline, pumping stations, and piers shall be designated and posted as Controlled 

Areas. Areas containing critical assets may be designated as a restricted area. 

Controlled and restricted areas are defined areas in which there are special restrictive 

measures employed to prevent unauthorized entry. Restricted areas may be of different 

types depending on the nature and varying degree of importance of the protected asset. 

Restricted areas must be authorized by the installation commander, properly posted, 

and shall employ physical security measures. 

UFC 4-020-01, DoD Security Engineering Facilities Planning Manual, supports the 

planning of DoD facilities that include requirements for security and antiterrorism. Use 

in conjunction with UFC 4-010-01, DoD Minimum Antiterrorism Standards for Buildings, 

to establish the security and antiterrorism design criteria that will be the basis for DoD 

facility designs.

UFC 4-010-01, DoD Minimum Antiterrorism Standards for Buildings, establishes the 

standards that provide minimum levels of protection against terrorist attacks for the 

occupants of all DoD inhabited buildings. Incorporate the minimum standards into the 

design of all new construction and major renovations of inhabited DoD buildings.

Coordinate with installation or activity Security and Antiterrorism Officer (ATO) to 

determine area designation (controlled or restricted), threat environment, Design Basis 

Threat (DBT), level of protection and access control requirements. 

2-6.2 Security Fencing

Unless otherwise directed by Service Headquarters, provide security fencing around all 

petroleum facilities to ensure safety and inhibit sabotage, theft, vandalism, or entry by 

unauthorized persons. Install a 7-foot (2.1 m) fabric height fence of chain-link type with 

three-strand barbed wire outriggers on top or its equivalent. Ensure fencing, gates, and 

associated clearance requirements are in accordance with MIL-HDBK-1013/10 or UFC 

4-020-03FA. Contact the Installation Security Organization for additional requirements.

2-7 MAINTAINABILITY CAPABILITIES

Provide adequate maintenance space around all equipment including:

a) Filter/separator and other filtration device maintenance access, 

particularly element removal. For vertical filtration devices provide stair 

and platform access to at least one side of each unit.
UFC 3-460-01

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b) Manual valves, especially replacement of slips in double block and 

bleed tapered lift plug valves.

c) Adequate room and locations for the use of an intelligent pig 

launcher/receiver in all section of piping.

d) Meter reading and maintenance.

e) Control valves.

f) Pumps, including removal.

g) Instruments, especially those mounted on tank shells. 

2-8 VOICE COMMUNICATIONS

Provide voice communications (direct line for Air Force projects only) between 

separated areas such as receiving, dispensing, pump stations, and fuel storage areas to 

coordinate operations involved in fuel transfer. Refer to UFC 3-501-01 and UFC 3-550-

01 or Corps TM 5-811-9. 

2-9 OTHER COMMUNICATIONS

2-9.1 Data Communications

Data communications systems shall be designed in accordance with the applicable 

Telecommunications Industry Association (TIA) and Electronic Industries Association 

(EIA) documents. Coordinate with local Base Communications squadron where 

applicable. For Army, Navy, and Air Force communication systems design criteria see 

USACE ETL 1110-3-502, Air Force LTA-AF and DoD UFC 3-580-01. 

2-9.2 Fire Alarm Communication

Fire alarm communications systems shall be coordinated with the Base Fire 

Department. For fire alarm communication system requirements see the relevant 

UFGS. 

2-10 VAPOR RECOVERY

Provide vapor recovery where required by federal, state, and local regulations (40 CFR 

Part 60 Subpart XX) and other chapters of this UFC. Refer to paragraph titled Air 

Quality Control in this chapter of the UFC.

2-11 WORKER SAFETY

Design facilities to comply with the most stringent of the Occupational Safety and Health 

Administration (OSHA) or the host nation standards. Also, ensure that design complies 

with service-specific occupational safety and health criteria. For Navy, OPNAVINST 

5100.23 Series Applies.

2-11.1 Safety Showers and Eyewash Fountains

Safety showers and eyewash facilities are required in workshops, laboratories, 

pumphouses, fueling piers and other similar facilities. Fixed safety showers and 
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eyewash facilities, or portable eyewash units, shall be installed at other locations where 

fuel is transferred to/from trucks, rail cars, and aircraft. Refer to Appendix D of UFC 3-

420-01, Plumbing Systems, for additional requirements associated with Emergency 

Shower and Eyewash Stations.

2-12 ELECTRICAL DESIGN

2-12.1 Area Classifications

Classify all fuel facilities, except as modified by this UFC, in accordance with API RP 

500, NFPA 30, NFPA 70, and ANSI/IEEE C2. These practices may be modified where 

unusual conditions occur, where locations contain hazardous atmospheres classified 

other than Group D (as defined by NFPA 70), or where equipment malfunction may 

cause hazardous situations. Use sound judgment in applying these requirements. 

Specify a higher classification wherever necessary to maintain safety and continuity of 

service. Treat combustible liquids under pressure as flammable liquids. All piping and 

equipment including that connected to an atmospheric storage tank shall be considered 

pressurized. Ensure design is in accordance with the requirements designated in NFPA 

70 for the specific division and class. Ensure equipment temperature class or operating 

temperature is in accordance with NFPA 70. Ensure that project drawings include 

hazardous area plans indicating extent and classification of areas. Drawings should 

provide dimensions indicating extent of classified areas and should include 

sections/elevations when required to fully convey the extent of the areas.

2-12.1.1 Class I, Division 1

Class I, Division 1 locations include:

a) Outdoor locations and those indoor locations having positive 

mechanical ventilation that is within 3 feet (0.9 m) of the fill openings or 

vents on individual containers to which flammable liquids are being 

transferred. Provide alarm devices on all ventilation systems.

b) Outdoor locations within 5 feet (1.5 m) of open end of vents and 

openings on liquid fuel storage tanks extending in all directions. 

c) Entire pit, sump, open trench, or other depression, any part of which is 

within a Division 1 or 2 location and is without mechanical ventilation.

d) Locations within and on exterior walls of open top spill containment 

structures including oil/water separators and spill containment boxes. 

e) Locations at fuel dispensers.

f) Locations within 3 feet (0.9 m) of vent, extending in all directions, when 

loading a truck through the bottom connection.

g) All pump/filter houses handling liquid fuels.
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h) Any area containing electrical equipment that is or may be exposed to 

atomized fuel and where the ambient temperature can at any time be 

above the flash point of the fuel.

2-12.1.2 Class I, Division 2

Class I, Division 2 locations include:

a) Outdoor locations between 5 feet (1.5 m) and 10 feet (3 m) of the 

Division 1 zones at vents and openings, on liquid fuel storage tanks

extending in all directions. 

b) Entire pit, sump, open trench, or other depression, any part of which is 

within a Division 1 or 2 location and is provided with mechanical 

ventilation.

c) Outdoor locations within 3 feet (0.9 m) of the exterior surface of 

pumps, air relief valves, withdrawal fittings, meters, and similar devices 

that are located in pipelines handling liquid fuels under pressure. 

Class I, Division 2 locations extend upward 18 inches (450 mm) above 

grade level and within 10 feet (3 m) horizontally from any surface of the 

device.

d) Locations within and extending upward to the top of the dikes that 

surround aboveground tanks containing liquid fuels and within 10 feet 

(3 m), extending in all directions of the tank shell, ends, or roof.

e) Locations extending upward 18 inches (450 mm) above grade level 

within 15 feet (4.6 m) horizontally from any surface of open top spill 

containment structures including oil/water separators and spill 

containment boxes, whether installed indoors or outdoors.

f) Locations 25 feet (7.6 m) horizontally in all directions on pier side from 

portion of hull containing cargo and from water level to 25 feet (7.6 m) 

above cargo tank at highest point.

g) Area between 3 feet (0.9 m) and 10 feet (3 m) extending in all 

directions from vent when loading a truck. Also upward 18 inches (450 

mm) above grade and within 10 feet (3 m) horizontally from the truck 

load connection.

2-12.1.3 Non-Classified Locations

Non-classified locations include:

a) Outdoor locations having closed piping systems handling flammable or 

combustible liquids that have no pumps, air relief valves, withdrawal 

fittings, valves, screwed fittings, flanges, meters, or similar devices 

which create joints in piping.
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b) Office buildings, boiler rooms, control rooms, and similar locations that 

are outside the limits of hazardous locations, as defined above, and 

are not used for transferring flammable or combustible liquids or 

containers for such liquids.

c) Areas in which flammable and combustible liquids are stored in 

accordance with NFPA 30, outside the limits of a classified location, 

and the liquids are not transferred.

2-12.2 Illumination

Illuminate all working areas for night operations to the minimum intensity recommended 

in Table 4 of API RP 540. Lighting design should also provide for road access on tall 

light posts to allow for lamp replacement. For facilities within the jurisdiction of the U.S. 

Coast Guard under 33 CFR Part 154, illuminate to the minimum intensity required by 

that regulation. Provide security lighting in accordance with MIL-HDBK-1013/1 for the 

Navy, UFC 3-550-03FA for the Army and Air Force and AFOSH Standard 91-38 for the 

Air Force. If local or state regulations exist, follow the most stringent requirements.

2-12.3 Grounding and Bonding

The following references apply to grounding and bonding systems:

a) ANSI/IEEE 142

b) NFPA 70

c) NFPA 77

d) NFPA 780

e) API RP 540

f) API RP 2003

g) ANSI/IEEE 1100

h) NFPA 407

2-12.3.1 Grounding Requirements

Ground the following items in accordance with Article 250 of NFPA 70: 

a) Motor, generator, and transformer frames.

b) Non-current-carrying metallic parts of electrical equipment and 

installations, such as enclosures for panelboards, switchgear, and 

motor control centers.

c) Metallic messengers of self-supporting cables.
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d) Exposed conductive materials enclosing electrical conductors, such as 

metallic conduit, metallic tubing, metallic armoring, sheaths and 

shields, cable troughs, trays and racks, wireways, and busways.

e) Filter/separators and other filtration equipment.

2-12.3.2 Current and Lightning Protection

Provide lightning protection in accordance with Corps TM 5-811-3, AFM 88-9, NFPA 

780, MIL-HDBK-1004/6, and local installation requirements. For fault current protection 

and lightning protection, ground the following items through ground rods or beds or 

bond to a grounded network. Provide ground for these items as required by the above 

references.

a) Fences.

b) Lightning arrestors and lightning shield conductors.

c) Operating mechanisms of overhead airbreak switches.

d) Canopies.

e) Aboveground storage tanks.

2-12.3.3 Static Electricity Prevention

To prevent the buildup static electricity, ground the following items directly through 

ground rods or beds or bond to a grounded network. Do not exceed 10,000 ohms of 

resistance to ground, unless otherwise stated. Do not bond dissimilar metals together.

a) Aboveground tanks, vessels, stacks, heat exchangers, and similar 

equipment not directly supported or bolted to a grounded supporting 

network.

b) Pipe and pipe support columns in accordance with the more stringent 

of NFPA 77 or below. 

(1) Provide (minimum) 1 ground rod on pipe runs 100 feet (30 m) 

long or less unless the pipe is connected to a grounded source 

within the 100 feet (30 m).

(2) Provide (minimum) 2 ground rods on runs of pipe that exceed 

100 feet (30 m), but are less than 300 feet (90 m) in length. 

(3) Provide (minimum) 1 ground rod at intervals not exceeding 300 

feet (90 m) on runs of pipe that are greater than 300 feet (90 m) 

in length. 

(4) Parallel pipes may be bonded and common ground rods used, 

spaced in accordance with (1) through (3) above. 
UFC 3-460-01

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c) Aircraft direct fueling stations.

d) Hydrant pits.

e) Internal floating pans bonded to the storage tank shell.

f) Aboveground portions of electrically isolated piping at truck, rail, and 

marine loading and unloading stations.

2-12.3.4 Installation 

Isolate grounding systems for instrumentation, instrument control boards, and electronic 

equipment from all other ground systems. Additional grounding is not required for 

overhead electrical equipment bolted directly to grounded metallic structures. Where 

feasible, separate the conductor connecting a lightning rod to the grounding electrode

from other grounding conductors. Route with a minimum of sharp bends and in the 

most direct manner to the grounding electrode. Do not use this electrode in lieu of 

grounding electrodes which may be required for other systems. This provision does not 

prohibit the required bonding together for grounding electrodes of different systems.

2-13 CATHODIC PROTECTION

Obtain the services of a National Association of Corrosion Engineers (NACE)-certified 

Corrosion Specialist or Cathodic Protection Specialist or a registered professional 

Corrosion Engineer to perform all cathodic protection design and testing. For Army and 

Air Force designs, comply with the current Engineering Technical Letters in addition to 

the following requirements. For Navy designs, comply with NAVFAC Interim Technical 

Guidance FY94-01.

2-13.1 Tanks 

For all underground steel tanks and tank bottoms of aboveground vertical tanks, provide 

cathodic protection in accordance with UFC 3-570-02N, API RP 651, 40 CFR Part 280, 

UL 1746, and UFC 3-460-03. For additional information on cathodic protection, refer to 

NAVFAC MO-230 and AFI 32-1054. Current tank design configuration electrically 

isolates the tank bottom from surrounding earth. Therefore, install cathodic protection

between the liner and the tank bottom.

2-13.2 Piping

For all carbon steel and stainless steel underground and underwater piping, provide 

cathodic protection in accordance with UFC 3-570-02N and 40 CFR Part 280 for piping 

associated with underground storage tanks. For additional information on cathodic 

protection, refer to NAVFAC MO-230, NACE SP0169 Control of External Corrosion on 

Underground or Submerged Metallic Piping Systems, and 49 CFR Part 195. Buried 

stainless steel corrodes and, therefore, must be cathodically protected.

2-13.2.1 Surge Arrestors

Provide surge arrestors across all aboveground insulated flanges connected to 

belowground cathodically protected piping. Require surge arrestors to be designed for 

use with insulated flanges and for use in Class I, Division 1 areas. Provide covers over 
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flanges to preclude dirt from degrading surge arrestors; refer to DoD Standard Design 

AW 78-24-28.

2-13.3 Structures

Obtain the services of a (NACE)-certified Corrosion Specialist or Cathodic Protection 

Specialist or a registered professional Corrosion Engineer to evaluate the need for 

cathodic protection on steel portions of fueling support facilities. Comply with UFC 3-

570-02N.

2-14 ENVIRONMENTAL PROTECTION

2-14.1 General Policy

It is the firm policy of the Department of Defense to design and construct fueling 

facilities in a manner that will prevent damage to the environment by accidental 

discharge of fuels, their vapors or residues. Designs must comply with foreign 

government, national, state, and local environmental protection regulations that are in 

effect at a particular facility.

2-14.2 Regulations

2-14.2.1 Within U.S.A.

Within the jurisdiction of the United States, adhere to the following environmental 

protection regulations:

a) National Environmental Policy Act (NEPA), 42 USC 4321. 

b) U.S. Coast Guard Regulations, 33 CFR Part 154. 

c) Environmental Protection Agency Regulations, 40 CFR Part 60. 

d) Environmental Protection Agency Regulations, 40 CFR Part 112. 

e) Environmental Protection Agency Regulations, 40 CFR Part 122. 

f) Environmental Protection Agency Regulations, 40 CFR Part 280. 

g) Environmental Protection Agency Regulations, 40 CFR Part 281. 

h) Department of Transportation Regulations, 49 CFR Part 195. 

i) Obtain additional data on anti-pollution regulations for specific 

locations from Service Headquarters Environmental Support Office.

2-14.2.2 Outside U.S.A. 

At facilities in other countries, consult appropriate service environmental directives, 

DODD Overseas Environmental Baseline Guidance Doctrine and for Navy, 

OPNAVINST 5090.1. It may be appropriate to address the DoD Overseas 

Environmental Baseline Guidance Document and appropriate Final Governing 
UFC 3-460-01

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Standards for the region/country. If tank is to be installed in a locale or state with more 

stringent criteria, use the more stringent criteria. If tank is to be installed in a NATO 

country other than the CONUS, follow the most stringent of local regulations or NATO 

Airfield Standard Design - Jet Fuel Storage and Dispensing Systems.

2-14.3 Transfer of Fuel at Ports

2-14.3.1 Bulk Transfer

Compliance with 33 CFR Part 154 is required for each fixed facility capable of 

transferring fuel in bulk to or from a vessel with a capacity of 10,500 gallons (39 700 L) 

or more. These facilities are required to have an operations manual approved by the 

Captain of the Port. In the operations manual, include the requirement for the following 

systems: 

a) Hose assemblies

b) Loading arms

c) Closure devices

d) Monitoring devices

e) Small discharge containment

f) Discharge removal

g) Discharge containment equipment

h) Emergency shutdown

i) Communications

j) Lighting

2-14.3.2 Vapor Collection

For facilities that collect vapor from vessel cargo tanks, ensure that the requirements of 

40 CFR Part 60 for the following items are met:

a) Vapor line connections

b) Vessel liquid overfill protection

c) Vessel vapor overpressure and vacuum protection

d) Fire, explosion, and detonation protection

e) Detonation arrestors, flame arrestors, and flame screens

f) Inerting, enriching, and diluting systems
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g) Vapor compressors and blowers

h) Vapor recovery and vapor destruction units 

2-14.4 Air Quality Control

2-14.4.1 Design Requirements

Regulatory requirements pertaining to air quality control will vary according to locality 

and to type and size of the petroleum vapor source. Petroleum storage and dispensing 

facilities are common sources of air pollution. Their emissions are typically restricted 

through requirements in state and local regulations. Federal regulations (40 CFR Part 

60 Subparts Kb and XX) may also apply depending on the product handled and size of 

the tank or facility being constructed.

2-14.4.2 Aboveground Storage Tanks

Federal regulation 40 CFR Part 60 Subpart Kb requires that tanks used for the storage 

of fuel with a design capacity greater than 19,000 gallons (72 000 L) having a true vapor 

pressure greater than 0.75 psia (5. kPa) at operating temperature must be equipped 

with either: 1) a fixed roof in combination with an internal floating pan; 2) an external 

floating roof equipped with a dual seal closure device between the wall of the tank and 

the roof edge; or 3) a closed vent system designed to collect all volatile organic 

compound (VOC) vapors and gases discharged from the tank and a control device 

designed to reduce VOC emissions by 95 percent or greater. It is the design intent that 

most vertical aboveground tanks will have internal floating pans and that vapor recovery 

will be used only if required by federal, state, or local regulations for the type of fuel and 

type of tank proposed, except as specifically required by another chapter of this UFC. 

Refer to Chapter 8 of this UFC for specific requirements for floating pans.

2-14.4.3 Truck and Rail Loading Facilities

Tank truck and tank car loading facilities constructed or modified after December 17, 

1980 which load an annual average of more than 20,000 gallons (76 000 L) per day of 

fuel having a true vapor pressure (TVP) of 0.75 psia (5 kPa) or greater must discharge 

the vapors resulting from such operations into a closed system. Ensure this system 

leads to a vapor recovery or disposal system which is capable of removing 95 percent 

of the petroleum vapor before final discharge into the atmosphere. Equip bulk gasoline 

terminals (handling fuels with TVP > 4.003 psia or 27.60 kPa) with a vapor collection 

system designed to collect total organic compound (TOC) vapors displaced from tank 

trucks during loading. Emissions from the vapor control system due to loading must not 

exceed 35 mg of TOC per liter of gasoline loaded. For facilities with an existing vapor 

processing system, the TOC emissions must not exceed 80 mg of TOC per liter of 

gasoline loaded (40 CFR Part 60 Subpart XX).

2-14.4.4 Permit Requirements 

Air quality permits are typically required for the construction of petroleum storage and 

dispensing facilities. It is essential for designers to review regulatory requirements to 

ensure incorporation of proper environmental controls. State and local regulations are 

primary sources for air quality requirements, but for particularly large facilities, it is also 
UFC 3-460-01

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beneficial to confer with the EPA regional office. The permit review and air quality 

controls will further depend on whether the construction site is located in an attainment 

or non-attainment area for ozone. Different permit programs apply in these areas, but 

they can both yield strict control requirements depending on the air quality of the area. 

An emissions offset analysis may be necessary before any construction permit can be 

granted. This analysis will require and demonstrate a reduction in VOC emissions from 

other sources in the locality where the new source construction is to take place. The 

offset can be obtained by providing new or better controls or otherwise decreasing 

emissions from an existing source.

2-14.5 Water Quality Control

2-14.5.1 Design Requirements

Protection of the natural waters against pollution from discharge of petroleum is 

achieved by complying with federal, state, and local regulations. 

2-14.5.2 Stormwater Discharge

A National Pollutant Discharge Elimination System (NPDES) Permit, 40 CFR Part 122, 

may be required for the discharge of stormwater. A review of federal, state, and local 

stormwater regulations is required prior to design and construction. Discharge of 

stormwater includes:

a) Controlled drainage from storage tank areas with impermeable diked

enclosures or drainage systems leading to impoundments.

b) Drainage from treatment systems. 

c) Drainage from facility transfer operations, pumping, and tank car and 

tank truck loading/off-loading areas.

d) Drainage from equipment/vehicle maintenance areas.

2-14.5.3 Spill Prevention Control and Countermeasures (SPCC) Plan

The minimum requirements for spill prevention in the United States are contained in 40 

CFR Part 112. It requires the preparation of a SPCC Plan for facilities that may 

discharge fuel into navigable waters of the United States. Specific design features are 

necessary to meet the SPCC objectives at all facilities. The SPCC plan must 

demonstrate that the fuel facility will be designed and constructed in a manner that will 

prevent spillage, and should such a spillage occur, prevent the spill from leaving the 

property and entering a waterway. Review API Bulletin D16 to assist with conformance 

to regulations. Refer to 33 CFR Part 154 for small discharge containment.

2-14.5.4 Meeting SPCC Plan Objectives

40 CFR Part 112 allows SPCC Plan objectives to be met by either spill containment or 

spill treatment. For facilities covered by this UFC only spill containment systems are 

acceptable. Spill treatment systems shall not be allowed to meet SPCC requirements 

unless required by regulations. Provide treatment systems (oil/water separators) to 

treat the discharge from spill containment systems only when required by federal, state, 
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or local regulations, or by Service Headquarters. Typical facilities requiring a spill 

containment system are fuel storage tanks, tank truck loading/off-loading/parking areas, 

and tank car loading/off-loading areas.

2-14.5.5 Spill Containment Systems

The SPCC Plan objectives expressed in 40 CFR Part 112 shall be met with 

impermeable spill containment system designed to prevent a spill from leaving the 

property unless a spill treatment system is required by federal, state, or local 

regulations, or by Service Headquarters. See the individual chapters of this UFC for 

requirements.

2-14.5.6 Spill Treatment Systems (Oil/Water Separators) 

Treatment systems (oil/water separators) may not be used to meet the requirements of 

40 CFR Part 112 unless required by federal, state, or local regulations, or as 

determined by the appropriate Service Headquarters. Do not provide oil/water 

separator to treat the discharge from spill containment systems (e.g. secondary 

containment dikes, tank truck parking areas, loading/off-loading facilities), unless 

specifically required by regulations. Select either a conventional rectangular API type

gravity oil/water separator or one with inclined parallel plates. Where possible, design 

the separator as a rectangular vessel with a fully open top with lid for ease of inspection 

and cleaning. 

a) Design and construct the separator in accordance with the following:

(1) UFC 1-200-01 and UFC 3-301-01. 

(2) UFGS 44 42 53. 

(3) Army Corps of Engineers ETL 1110-3-466. 

(4) ACI 350.4R-04, Design Considerations for Environmental 

Engineering Concrete Structures.

b) Consider the following items in sizing the oil/water separator: 

(1) Anticipated inlet flow rate of a 5-year, 1-hour duration storm 

event.

(2) Type of fuel.

(3) Specific gravity and viscosity of fuel.

(4) Specific ambient and product temperature ranges.

(5) Product storage capacity required.

(6) Possible contaminants present.

(7) Operating parameters are intermittent or continuous.
UFC 3-460-01

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c) Require parallel plates to be constructed from non-oleophilic materials

such as fiberglass. Arrange the plates in either a downflow or 

crossflow mode so that the oil collects in the high point of the 

corrugations and rises to the top without clogging from settleable 

solids.

d) Consider installing a retention basin upstream of the oil/water 

separator. This would allow solids to settle prior to reaching the 

oil/water separator and allow the option of either releasing the 

stormwater to the oil/water separator or to an appropriate stormwater 

collection system.

2-14.5.7 Leak Detection

As required by federal, state, and local regulations install leak detection on 

aboveground tank bottoms, underground storage tanks, and underground piping. 

2-14.5.8 Wastewater Disposal

Provide a holding tank for wastewater. Wastewater is any water which has been in 

contact with significant quantities of fuel such as water collected from tank sumps, 

equipment drains, and equipment sumps. Ensure that tank construction conforms to 

federal, state, and local environmental requirements. Provide a means to remove 

wastewater for off-site disposal.

2-14.5.9 Dewatering

Where dewatering for construction purposes is necessary and contamination is 

suspected, test the groundwater prior to construction to determine the extent of 

contamination. If the groundwater is, or has the potential to be, contaminated with 

petroleum products, review federal, state, and local regulations for acceptable treatment 

methods. Permits may be required for treatment and/or disposal of the water. Contact 

facility Environmental Department for guidance.

2-14.6 Aboveground Storage Tanks

2-14.6.1 Design Requirements

Aboveground storage tanks may be single wall, double wall, horizontal, vertical, 

protected, or fire resistant as discussed in Chapter 8. There is not a single federal 

regulation that specifically addresses aboveground storage tanks similar to 40 CFR Part 

280 that solely governs underground storage tanks. The majority of the federal 

environmental design requirements come from either 40 CFR Part 112 or 29 CFR Part 

1910.106. These regulations include environmental related requirements for:

a) Diking and drainage.

b) Flooding.

c) Corrosion Protection.

d) Inspections, Tests, and Records.
UFC 3-460-01

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e) Brittle Fracture Analysis.

The designer must consult the latest version of these regulations and comply with all 

federal, state, and local regulations. 

2-14.6.2 Other Requirements

If a tank is to be installed in a locale or state with more stringent criteria, use the more 

stringent criteria. If tank is to be installed in a NATO country other than the CONUS, 

follow the most stringent of local regulations or NATO Airfield Standard Design - Jet 

Fuel Storage and Dispensing Systems.

2-14.7 Underground Storage Tanks

2-14.7.1 Design Requirements

All underground and cut and cover storage tanks are to be double wall type. Single wall 

underground storage tanks are not allowed. For underground storage tanks larger than 

110 gallons (416 L), the following are required by 40 CFR 280:

a) Corrosion protection for tanks and associated underground piping.

b) High level alarm.

c) Spill and overfill protection.

d) Release detection.

2-14.7.2 Other Requirements

If a tank is to be installed in a locale or state with more stringent criteria, use the more 

stringent criteria. If tank is to be installed in a NATO country other than the CONUS, 

follow the most stringent of local regulations or NATO Airfield Standard Design - Jet 

Fuel Storage and Dispensing Systems.

2-15 FIRE PROTECTION

2-15.1 General Requirements

Design all petroleum fuel storage, handling, transportation, and distribution facilities with 

full consideration of the hazardous nature of the fuels to be handled and their vapors. 

Ensure compliance with UFC 3-600-01.

2-15.2 Protection of Aboveground Storage Tanks

2-15.2.1 Tank Exterior Fire Protection Water Systems

Provide fire protection water mains, hydrants, valves, pumps, and application devices to 

permit control of brush and grass fires and cooling of storage tanks in the event of a fire 

exposure. Provide a minimum of two hydrants. Locate hydrants and valves outside of

diked areas and accessible to fire department pumper vehicles. Locate hydrants so that 

protected exposures can be reached through hose runs not exceeding 300 feet (90 m). 

Comply with all requirements of UFC 3-600-01 for water supply.
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2-15.2.2 Tank Interior Fire Protection Systems

Tanks containing Class I flammable fuels or mission-critical Class II combustible fuels, 

such as JP-8, shall be equipped with a full contact, aluminum honeycomb floating pan. 

Other Class II fuels require a floating pan if the tank does not comply with the spacing 

and diking requirements of this UFC. Tanks storing mission-critical Class III fuels, such 

as JP-5 and diesel fuel marine (F-76), if located in hot (desert-like) climate, also require 

a floating pan to eliminate the fuel/air interface. A single slotted stilling well, that 

penetrates the floating pan, has a maximum diameter of 10 inches (250 mm) and is 

used for the automatic tank gauge system, is allowed to be provided without a vapor 

sleeve (bellow). The slotted well used for manual measurements shall be equipped with 

a floating plug.

2-15.3 Fire Protection of Pumping Facilities

Fuel pump houses where over 50% of the fuel hydrant pumping capacity is in one fire 

area and that area is enclosed shall be protected with an automatic fire suppression 

system, such as a fire sprinkler system, foam water fire suppression system, etc. Fuel 

pump houses where over 50% of the transfer pumping is in one (enclosed) fire area 

shall be protected with an automatic fire suppression system, foam water fire 

suppression system, etc. Readily available mobile pumping equipment with 50% of the 

total pumping capacities can be used to eliminate need for a fire suppression system. 

Where mobile pumping option is selected, provide connection points in the fuel system 

for temporary mobile pumps in the event that a pump facility is lost. Pump pads and 

pump shelters do not need fire suppression systems.

2-15.3.1 Pumphouses, Pump Shelters, and Pump Pads

A pump pad has no roof or canopy. A pump shelter has a roof, at least one wall 

completely open with adequate fire department access, and a total open wall area of 50 

percent or more. A pumphouse has a roof, and a total open wall area of less than 50 

percent. 

2-15.3.2 Fire Department Access

Provide adequate fire department access for all pumping facilities. Provide fire 

department access to all open sides of a pumphouse or pump shelter. Provide fire 

department access to at least two sides of a pump pad.

2-15.4 Fire Protection of Underground Vertical Storage Tanks

2-15.4.1 Fire Protection Water Systems

Provide fire protection water mains, hydrants, valves, pumps, and application devices to 

permit control of brush and grass fires and for cooling of the aboveground piping and 

equipment associated with underground vertical storage tanks in the event of a fire 

exposure. Provide a minimum of two hydrants. Locate hydrants so that protected 

exposures can be reached through hose runs not exceeding 300 feet (90 m). Comply 

with all requirements of UFC 3-600-01 for water supply except that the minimum fire 

flow rate and minimum duration per hydrant shall be calculated using the smallest 

diameter of aboveground POL tank.
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2-15.5 Protection of Tank Truck and Tank Car Facilities

For facilities (such as loading stands) used for the transfer of flammable or combustible 

liquids to or from tank truck, refuelers, tank cars, drums, or other portable containers, 

provide portable dry chemical extinguishers of appropriate size, number, and location 

for the exposure. 

2-15.6 Protection of Aircraft Fueling Facilities

Provide fire fighting equipment in accordance with service requirements. Refer to USAF 

AFTO 00-25-172, NAVAIR 00-80R-14, NAVAIR 00-80T-109, AR 420-90 and NFPA 407. 

2-15.7 Protection of Fuel Testing Laboratory 

Laboratories shall comply with the general facility requirements of UFC 3-600-01 and 

NFPA 45 Laboratories using Chemicals.

2-15.8 Protection of Support Facilities

Comply with UFC 3-600-01 for fire protection of support facilities.

2-15.9 Protection of Fuel Piers

Provide protection for piers with fixed piping systems used for the transfer of flammable 

or combustible liquids in accordance with the following:

a) UFC 3-600-01

b) UFC 4-152-01, UFC 4-150-02, and UFC 4-150-06

c) NFPA 30

d) NFPA 30A

e) NFPA 307 (If liquids are handled in bulk quantities across general 

purpose piers and wharves.)

2-15.9.1 Fire Protection Water Systems

Use fire water systems with hydrants located so that vessels alongside can be reached 

through hose lines not longer than 300 feet (90 m). Consult UFC 3-600-01 to determine 

total water demands for piers based on an extra hazard occupancy classification.

2-16 EMERGENCY SHUT-DOWN

Emergency fuel shutoff (EFSO) pushbuttons are required wherever there is a potential 

for an accidental release. EFSO pushbutton stations are required near tanks (outside of 

berm area), tank car and tank truck loading and off-loading, refueler truck fillstands, 

aircraft direct fueling stations, pumps, fuel piers, etc. All pumps shall shut down and all 

motor operated valves shall close when an EFSO pushbutton is pressed. An alarm 

shall be annunciated at the master alarm panel. Operation of all pumps and valves 

shall be discontinued until all EFSO pushbuttons are cleared and the alarm 

acknowledged. Off-base pipeline receipt and tanker receipt may be exceptions; contact 

Service Headquarters for direction.
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2-17 ELECTROMAGNETIC RADIATION HAZARDS

Potential ignition hazards to petroleum storage, dispensing, or handling facilities may be 

created by emissions from electromagnetic devices such as radio and radar. 

Beam/signal strength has been known to cause ignition of flammable vapor-air mixtures 

from inductive electrical heating of solid materials or from electrical arcs or sparks from 

chance resonant connections. For additional information, refer to MIL-STD-461 and 

NFPA 407. Incorporate the following specific precautions and restrictions in the design 

of petroleum fuel facilities:

a) Locate the radio transmitting antennas as far as practically possible 

from fuel storage or transfer areas.

b) Do not locate the fuel storage or transfer facilities closer than 300 feet 

(90 m) from aircraft warning radar antennas.

c) Do not locate fuel storage or transfer facilities closer than 500 feet (150 

m) from airport ground approach and control equipment.

d) Do not locate fuel storage or transfer facilities closer than 300 feet (90 

m) from areas where airborne surveillance radar may be operated.

e) Do not locate fuel storage and transfer facilities closer than 100 feet 

(30 m) from airport surface detection radar equipment.

2-18 IDENTIFICATION

Identify all pipelines and tanks as to product service by color coding, banding, product 

names, NATO designation, and directions of flow in accordance with MIL-STD-161. 

Mark valves, pumps, meters, and other items of equipment with easily discernible 

painted numbers or numbered corrosion-resistant metal or plastic tags attached with a 

suitable fastener. Ensure numbers correspond to those on the schematic flow diagrams 

and other drawings for the installation.

2-19 ANTISTATIC DESIGN

Consider static build-up in the design. Refer to CRC Report No. 346 and No. 355, API 

RP 2003; and NAVFAC MO-230. Because of the many variables involved, such as 

properties of fuels and geometry of equipment layouts, no specific limits are established 

for design factors such as flow velocities. 

2-19.1 Piping Inlet Connections

Design connections to tanks for reduced velocity and to prevent splashing by use of 

diffusers. Fuel products are not permitted to free fall under any circumstances. Position 

inlet as close to the tank floor as possible to limit free fall.

2-19.2 Enclosed Vapor Spaces

Spaces above flammable or combustible Hydrocarbons in tanks or other liquid 

containers must not have any pointed projection or probes which could be focal points 

for static electricity discharges.
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2-19.3 Filter/Separators 

The heaviest electrostatic charges are usually developed in filtering elements of this 

equipment. The design should attempt to reduce such charges before fuel is 

transferred into storage tanks, vehicle tanks, or any equipment containing vapor spaces.

a) By means of residence time in piping or in a relaxation tank, provide a 

minimum of 30 seconds relaxation time between this equipment and 

discharging into a tank or vehicle. The only aviation turbine fuel 

currently in the inventory that requires this minimum relaxation time are 

JP-5, JPTS and other aviation turbine fuels that do not contain SDA.

b) Relaxation time is not required for projects handling only fuels 

containing a static dissipator additive that provides a conductivity level 

greater than 50 conductivity units (50 picosiemens per meter) at the 

fuel temperature of the operations. Examples of this are JP-4 and JP8.

c) Provide a means for slow filling, to prevent static discharge when first 

filling empty filter-separator vessels. 

2-19.4 Aircraft Direct Fueling Stations

JP-5 requires a 30-second residence time in the piping or in a relaxation tank after 

flowing through filtration and before being discharged into the aircraft to allow separate 

charges generated by the filtering elements to recombine and neutralize themselves. 

Where possible, design the piping layout to provide the required 30-second relaxation 

time without use of a relaxation tank.

2-19.5 Truck Bottom Loading

Provide facilities only capable of bottom loading of trucks. Army facilities that routinely 

handle trucks that are not capable of bottom loading must obtain approval for the 

addition of top loading capability from the Army Service Headquarters. Refer to NFPA 

77 and API RP 2003 for additional information and requirements.

2-20 OPERATION AND MAINTENANCE DOCUMENTATION

2-20.1 Equipment Operation and Maintenance Documentation

In all construction and procurement contracts, require operation and maintenance data 

for pieces of equipment which require maintenance and/or which require setting, 

adjusting, starting, stopping, calibrating, and similar operational activities.

2-20.2 Operation and Maintenance Support Information (OMSI)

An OMSI for all new facilities is required. The determination to include a requirement 

for a complete OMSI for new facilities or a major rehabilitation will be made by the 

appropriate Service Headquarters.

2-21 PROTECTION AGAINST SEISMIC ACTIVITY

Design fuel facility buildings and structures for seismic requirements in accordance with 

UFC 1-200-01. Design aboveground vertical storage tanks in accordance with API Std 
UFC 3-460-01

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650, Appendix E. Analyze flexible aboveground pipelines using techniques to account 

for harmonic response.

2-22 STRUCTURAL DESIGN

Design all buildings and structures in accordance with UFC 1-200-01. 

2-23 CONCRETE

Concrete where used in this UFC refers to cast-in-place, Portland Cement Concrete 

(PCC), reinforced as required, finished, and cured. The use of coated or uncoated 

bituminous asphalt concrete (asphalt), “shotcrete”, or autoclaved cellular concrete 

(ACC) in its place is prohibited.

2-24 AIRFIELD/AIRSPACE REQUIREMENTS

Incorporate requirements for airfield and airspace clearances into all construction 

documents for work near an airfield. Verify compliance with UFC 3-260-02.

2-25 PERMITS

The planner, programmer, and designer should give consideration to required permits 

(dredging, air emissions, water discharges, etc.). Considerations are cost of permit, 

cost impact of project to meet permit requirements, schedule impact of permit, who is to 

obtain permit, and at what time in the project schedule should application be made.
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CHAPTER 3 - BULK FUEL STORAGE FACILITIES

3-1 INTRODUCTION

This chapter provides guidance for the design of bulk fuel storage facilities, including 

bulk storage tanks and those components normally located within a typical bulk storage 

compound. These components include pipeline receiving facilities, tank truck and tank 

car receiving facilities, pipeline dispensing (pumping) facilities, tank truck and tank car 

loading facilities, and all related piping and equipment. Fuel storage tanks are 

discussed in Chapter 8 and piping systems in Chapter 9 of this UFC. Support facilities, 

which are discussed in Chapter 11 of this UFC, are often collocated within bulk facilities. 

Systems used to receive and dispense aviation turbine fuels are discussed in Chapter 4

of this UFC. Systems used to receive and dispense fuel from barges and ships are 

discussed in Chapter 5 of this UFC. Installation pipelines connecting bulk facilities with 

marine receiving and dispensing facilities, aircraft fueling facilities, and ground vehicle 

fueling facilities, as well as interterminal pipelines are discussed in Chapter 6 of this 

UFC. Refer to Facility Plate 001 for the entire chapter identification plan pertaining to 

this UFC.

Note: If aviation fuel can be pumped directly from a tank into an aircraft, aircraft direct 

fueling system or a refueler, treat the tank as an operating storage tank regardless of 

size and location and must meet the applicable requirements for aviation turbine fuel 

operating tanks. The exception is bulk storage tanks that are configured to fill refuelers 

on an emergency basis only.

3-2 GENERAL REQUIREMENTS

Chapter 2, General Design Information, contains important information on fueling 

facilities. Do not begin the design of any fueling system without first becoming 

completely familiar with Chapter 2 of this UFC.

3-3 RECEIVING FACILITIES

Fuel is normally received at bulk fuel storage facilities by pipeline, tank truck, tank car, 

barge, or ship. In many cases, the fuel is pumped by pipeline from the marine receiving 

facility to the bulk storage facility. Marine receiving facilities are addressed in Chapter 5 

of this UFC. Service Headquarters, with concurrence from the Defense Energy Support 

Center, will determine the appropriate type of delivery method based on mission 

requirements and an economic analysis. A secondary method of delivery is normally 

required for aviation activities.

3-3.1 Pipeline Receiving Facilities

3-3.1.1 General Criteria

Petroleum fuels may be supplied to bulk fuel storage tanks by interterminal pipelines

which may be dedicated to serving the particular facility or may be commercial pipelines 

handling a number of types or grades of fuel for more than one user. In some cases, 

the pipeline will be an installation pipeline. If different fuel types are used, separate 

each type within the receiving facility. Exercise extreme care to avoid designing a 
UFC 3-460-01

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system that could create damaging surges in the pipeline created by quick closing 

valves.

3-3.1.2 Equipment Required

a) Provide pressure-regulating diaphragm control valves to reduce 

pipeline pressures to the design pressure of the facility’s piping and 

equipment. Provide a manual isolation valve at both the upstream and 

downstream side of each diaphragm control valve. Prior to designing 

any features into the system which might affect the flow from a 

pipeline, contact the operator of the pipeline to ascertain the current 

operating conditions, evaluate the use of diaphragm control valves, 

conduct a surge analysis of the pipeline, and determine whether the 

use of diaphragm control valves is appropriate.

b) Provide a meter at the receiving end of the line to measure quantities 

of fuel received. Turbine-type meters are commonly used for pipeline 

receipt. However, positive displacement meters are acceptable if 

available at the required flow rate. Consider also the use of alternative 

meter technologies such as ultrasonic meters. Compensate for fuel 

temperature at the point of custody transfer. Provide a basket strainer 

on the upstream side of the meter and connections for proving the 

meter with a portable prover. A meter prover connection consists of a 

manual isolation valve in the main pipeline with a tee on both the 

upstream and downstream sides of the valve. The branch of each of 

the tees has a manual isolation valve and a hose connection. The 

master meter can be attached to the hose connections.

c) Provide a means for sampling each pipeline product at a breakout 

manifold.

d) Provide provisions for a contractor to bolt pig launchers and receivers 

to the system for pigging. Arrange pig receiving connections to avoid 

introducing pipeline sludge and sediment into the tanks. Pig launching 

and receiving provisions are required for interterminal (cross-country) 

and installation (as described in Chapter 6 of this UFC) underground 

pipelines.

e) Provide an interface tank to receive mixed fuels at the beginning and 

end of a shipment unless the commercial pipeline company can 

provide this service satisfactorily.

f) Provide a breakout tank only if pipeline flow cannot be stopped due to 

pipeline operational requirements. Provide valves to divert the flow of 

fuel from the pipeline to the breakout tank in the event fuel transfer is 

blocked by a manual or automatic valve within the fuel facility system 

such that the fuel facility system would be overpressurized from 
UFC 3-460-01

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transient surge or high pressure from deadheading a pipeline supply 

pump. Provide appropriate breakout tank overfill alarms and alarm 

breakout operation so fuel facility operators can take necessary steps 

to stop pipeline flow. Provide means of transferring fuel out of 

breakout tank back to fuel systems after a breakout event. Conduct a 

thorough review with the pipeline operator and perform a transient 

surge analysis to determine if surge pressure reduction methods are 

required to avoid damage to the pipeline.

g) Provide means of inbound filtration for all products. The selection of 

filtration depends on anticipated impurities, the source of fuel, and the 

shipping methods. Consider the use of micronic filters, cyclonic filters, 

and haypack coalescers as possible filtration devices. Avoid the use of 

water slug shutoff diaphragm control valves or other rapid-closing 

valves on pipeline receipt facilities. For inbound filtration of aviation 

turbine fuels, refer to “Special In-Bound Filtration” paragraph of 

Chapter 4 of this UFC. 

h) Provide manual isolation valves to isolate equipment for service.

i) Provide basket strainers upstream of pumps, meters and receipt 

filtration.

j) Provide thermal relief valves around isolation and check valves to 

relieve excessive pressures caused by thermal expansion of liquid 

trapped between shutoff points. See Facility Plates 023, 024, 025 and 

026. 

k) Provide a concrete housekeeping pad and, unless otherwise directed 

by Service Headquarters, a canopy to protect fixed facilities assets and 

equipment from the elements. See the “Canopies” paragraph of this 

chapter.

3-3.2 Tank Truck and Tank Car Off-loading Facilities

3-3.2.1 General Criteria

Bulk fuel storage facilities may be supplied with fuel by tank truck or tank car or both. At 

facilities with pipeline or water transport as their principal supply source, provide tank 

truck or tank car deliveries as a secondary supply source. Tank truck deliveries are the 

most common method. However, special transportation considerations or changing 

circumstances may make the use of rail facilities desirable. Therefore, at an activity 

with railroad service, arrange a tank truck receiving facility so that the system can be 

easily and economically extended to the existing rail spur. See Facility Plate 002. 

a) The preferred off-loading method is into a drop tank off-loading system. 

See Facility Plate 003. 
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b) Provide a packaged off-loading system when a drop tank type offloading is not practical for off-loading tank trucks or tank cars due to 

environmental concerns, site limitations, or cost considerations, and/or 

directed by Service Headquarters. See Facility Plate 004. 

c) Provide a direct off-loading system when only an occasional tank truck 

requires off-loading and when directed by Service Headquarters. See 

Facility Plate 005. 

d) Do not locate tank truck or tank car receiving facilities closer than 50 

feet (15 m) from tanks, buildings, roads, overhead power lines, padmounted transformers, and property lines. Comply with NFPA 30 and 

assume that the property line is the fuel farm fence. Use the criteria for 

Class I liquids regardless of product and do not take a reduction for 

fixed fire protection.

e) Provide an adequate number (minimum two) of positions to off-load the 

daily fuel requirements of the facility in an eight-hour period without 

causing detention or demurrage of delivery conveyances.

f) Provide separate off-loading connections for each type of fuel to be 

handled. To facilitate the use of tank trucks with multiple independent 

compartments, provide a hose manifold with a minimum of two 

connections per tank truck. A manifold with hose connections equal to 

the number of truck compartments is recommended for quick 

turnaround. If less than five connections are provided, provide a blind 

flange on the end of the manifold to accommodate additional 

connections.

g) Provide a containment area at each truck off-loading position

consisting of an impermeable retention and controlled drainage system 

leading to a concrete remote spill containment system. Pave the 

containment area consisting of the islands, the spaces between islands 

and on each side of the outer islands, with concrete pitched a minimum 

of one percent toward catch basins or trench drains. Design the 

containment area in accordance with UFC 1-200-01, federal, state, and 

local regulations. Do not use asphalt within a spill containment area. 

The maximum slope of any paving within a truck movement or parking 

area shall not exceed 2 percent excepting rollover curbs. If a rollover 

curb is provided, the sum of the vertical entrance and exit grades shall 

not exceed 8 percent, the horizontal length of the curb in the direction 

of truck movement shall not be less than 15 feet, and the rollover curb 

shall be aligned perpendicular with direction of truck movement. 

h) At tank car off-loading areas, pave the containment area with concrete 

(or otherwise provide containment) for an area extending from 5 feet 

(1.5 m) outside of each outer rail and extending longitudinally 15 feet 
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(4.6 m) each way from the center of each loading position. Slope the 

paved area to a to a spill containment system as described previously. 

i) Provide a concrete remote spill containment system for each 

containment area. Design the remote spill containment system in 

accordance with UFC 1-200-01, federal, state, and local regulations. 

Provide the remote spill containment system with capacity greater than 

either the volume of the largest tank truck or tank car compartment to 

be off-loaded, or runoff from a rainfall of intensity equal to a 5-year 

expectancy, 1-hour duration storm. Provide a lockable knife gate valve 

with indicator post located outside the enclosure in an area that will be 

safely accessible during a fire. The valve shall be lockable and 

normally closed to allow for containment during fueling operations and 

which can be opened to drain the area when necessary. Tank trucks 

can be as large as 10,000 gallons (38 000 L) in capacity and tanks 

cars as large as 40,000 gallons (150 000 L). If a canopy is installed, 

reduce the sizing for rainfall, accounting for wind-blown rain. Consider 

combining the remote spill containment system with other spill 

containment systems on site, except with tank containment systems. 

However, take the level of contamination in each containment area into 

consideration.

j) Construct the drain piping between the containment area and the 

concrete remote spill containment system, and between the remote 

spill containment system and lockable knife gate valve of petroleumresistant, fire-resistant, impermeable materials. Do not use clay, 

concrete, fiberglass, or plastic piping materials.

k) For off-loading tank trucks, arrange the flow of traffic to permit 

continuous forward movement of tank trucks at all times. Commercial 

tank trucks off-load on the passenger side.

l) To determine the number of connections needed for off-loading tank 

cars, consult with Service Headquarters and consider minimizing tank 

car movements, tank car shipping schedules, conveyance turn-around 

times, local rail switching capabilities, and quantity of fuel needed for 

one day’s fuel supply.

m) Provide an electrical design that meets the minimum requirements of 

NFPA 70, NFPA 77, and NFPA 780. Treat combustible liquids under 

pressure as a flammable liquid. 

n) Provide a canopy for protection from the elements of fixed facility 

assets and equipment per the “Canopies” paragraph of this chapter. 

o) Provide a canopy to preclude rain from the containment area when the 

requirements listed in the “Canopies” paragraph of this chapter are 

met.
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p) Provide for egress and entrance of emergency response vehicles. The 

egress and entrance routes need to be large enough to allow both, 

trucks and emergency vehicles, leaving and entering the facility.

q) Provide a means of inbound filtration for all products. The selection of 

filtration depends on anticipated impurities, the source of fuel, and the 

shipping methods. Consider the use of micronic filters, cyclonic filters, 

and haypack coalescers as possible filtration devices. For inbound 

filtration of aviation turbine fuels, refer to Chapter 4 of this UFC. 

3-3.2.2 Tank Truck and Tank Car Drop Tank Off-Loading System

The introduction of air into a fuel receiving system poses extreme hazards which can 

result in fire and/or explosion. Hazards are compounded when an air/fuel mixture is 

passed through receipt filter/separators where static electricity is generated and ignition 

can occur. Design off-loading facilities so air is not introduced into the system. For 

facilities with the capability to off-load several tank trucks at once or where newer tank 

trucks with multiple hoses are connected to multiple isolated compartments, consider 

providing an underground, gravity-type, receiving tank with submersible transfer pumps 

and level controls. For smaller systems of one or two tank trucks, consider a low profile, 

aboveground, receiving tank with a centrifugal transfer pump. For either case, provide 

level sensors to control the flow. Provide a temperature compensated meter on the 

receipt line to the tank at points of transfer and custody. For materials of construction 

for off-loading drop tanks, refer to Chapter 8. See Facility Plate 003. 

3-3.2.3 Tank Truck and Tank Car Packaged Off-Loading System

For tank truck or tank car off-loading, an off-loading drop tank may not be practical due 

to environmental concerns, site limitations, or cost considerations. In these instances, 

provide a 600 gpm (38 L/s) packaged off-loading system. Provide one packaged 

system, including vertical inline centrifugal pump, diaphragm control valves to control 

flow, meter, and multiple hose connections (one for each tank truck compartment), for 

each tank truck or tank car receiving station. Provide an air eliminator tank to remove 

air from the system, reducing the risk of an air/fuel mixture passing through receipt 

filter/separators and preventing the metering of air. Level sensors in the air eliminator 

tank control the pump discharge diaphragm control valves, modulating the flow rate 

based on the level in the air eliminator tank. Refer to NAVFAC Drawing No.1404005

and Facility Plate 004. 

3-3.2.4 Tank Truck and Tank Car Direct Off-Loading System

Use when only an occasional tank truck requires off-loading and when directed by 

Service Headquarters. Refer to Facility Plate 005. 

3-3.2.5 Equipment Required

a) When tank trucks or tank cars are off-loaded with a drop tank offloading system, do not provide an off-loading pump. Provide at least 

two pumps in the drop tank to transfer fuel to the storage tank.
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b) When tank trucks or tank cars are off-loaded with packaged off-loading 

systems, provide one system for each tank truck or tank car that is to 

be off-loaded simultaneously, at an average capacity of 600 gpm (38 

L/s) each. The number of systems shall be determined by Service 

Headquarters but shall be a minimum of two. The capacity of the 

systems may be reduced to 300 gpm (19 L/s) each only when directed 

by Service Headquarters. 

c) When tank trucks or tank cars are off-loaded with direct off-loading 

systems, provide centrifugal pumps configured to provide automatic air 

elimination as shown on Facility Plate 005. Provide at least two pumps 

to allow continued operation if one is out of service. The capacity of 

the pumps may be increased to 600 gpm (38 L/s) each only when 

directed by Service Headquarters. The centerline height of suction line 

from manifold to pump should not exceed 23.25 inches (591 mm) 

above truck unloading, parked position. Locate the pump as close as 

possible to the off-load point to prevent suction problems.

d) Provide 4-inch (100 mm) diameter by 10-foot (3 m) long lightweight 

reinforced vacuum rated off-loading hoses and covered hose storage 

racks for each hose connection at each off-loading position. Eliminate 

covered hose storage rack if off-load rack is to be covered by a 

canopy. Ensure that all swivels are non-lubricated aluminum or 

stainless steel in-line repairable type. Consult with Activity to verify the 

need for hoses, since at some locations, the fuel hauling contractor 

provides the hoses.

e) Equip each tank truck off-loading position with an electronic, 

intrinsically safe, automatic, self-monitoring ground verification unit with 

a lockable bypass. If grounding is not verified and there is an offloading pump dedicated to that position, ensure the unit prevents the 

pump from starting. If the pump is not dedicated, ensure an alarm 

sounds if the off-loading valve is opened prior to grounding verification. 

Include a separate grounding reel to accommodate vehicles without 

grounding equipment.

f) Provide emergency fuel shutoff (EFSO) pushbutton stations. For truck 

off-loading with multiple positions, an EFSO pushbutton station is 

required for each position and along routes of personnel ingress and 

egress between 100 and 200 feet from the off-loading position. Design 

in such a manner that activation of the emergency stop will shutoff all 

fueling in the off-loading area and/or the associated pumphouse or 

pump pad.

g) Provide fuel sampling connections at each position for each product 

line for collecting test samples.
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h) Provide pressure gauges on both sides of each strainer or a differential 

type gauge across each strainer. Where a strainer is upstream of a 

pump, the pump suction gauge may function as the strainer 

downstream gauge.

i) Provide a compound (pressure/vacuum) gauge on the inlet side of 

pumps and a pressure gauge on the outlet side of pumps.

j) If the system is for JP-5 or other fuel that does not have a static 

dissipater additive which provides a conductivity level greater than 50 

conductivity units (50 picosiemens per meter), and a 30-second 

retention time is not provided between filter/separator and receiving 

tank, provide a relaxation tank downstream of filter/separator to ensure 

a combined 30-second retention time (time in the relaxation tank and 

time in the piping). 

k) Provide basket strainers upstream of pumps, meters, and receipt 

filtration. 

l) Provide a combination flow control and non-surge check diaphragm 

control valve on all off-load pumps except positive displacement types. 

If a bulk air eliminator with automatic air release head is included, 

provide a means of closing the diaphragm control valve with a solenoid 

pilot.

m) Provide a positive displacement or turbine meter and meter proving 

connections. Provide meter with temperature compensation capability 

wherever custody transfer occurs. Provide a basket strainer on the 

upstream side of the meter.

n) On each off-loading connection or on the off-loading riser, install a 

visual fuel flow indicator (maximum pressure 275 psi (1900 kPa) at 100 

degrees F (38 degrees C), with Viton Seals with a maximum 

temperature rating of 350 degrees F (177 degrees C)). This will allow 

visual quality assurance and provide the operator with a backup 

system to shut off the pumps when off-loading is complete to prevent 

air build-up in the receipt lines.

o) Provide manual isolation valves to isolate equipment for service.

p) Provide thermal relief valves around isolation and check valves to 

relieve excessive pressures caused by thermal expansion of liquid 

trapped between shutoff points. See Facility Plates 023, 024, 025 and 

026. 

3-3.3 Marine Off-loading Facilities

See Chapter 5 of this UFC.
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3-4 DISPENSING FACILITIES

Fuel is normally dispensed from a bulk facility via an installation pipeline, interterminal 

pipeline, tank truck, or tank car.

3-4.1 Pipeline Pumping Facilities

3-4.1.1 General Criteria

As discussed in Chapter 6 of this UFC, pipelines are either interterminal pipelines or 

installation pipelines. Installation pipelines are commonly used to transfer fuel to an 

aircraft fueling facility or a marine dispensing facility. Interterminal pipelines are crosscountry between installations. However, since pipeline pumping facilities are typically at 

a bulk fuel storage facility, they are covered in this chapter.

3-4.1.2 Equipment Required

a) Centrifugal pumps complying with API Std 610 with adequate head 

and capacity. Always provide one additional pump as back-up.

b) Turbine or positive displacement meter with proving connections. 

Consideration can also be given to alternative meter technologies such 

as ultrasonic meters. Compensate for fuel temperature at custody 

transfer point.

c) Provide fuel sampling connections for collecting test sample.

d) Pig launching and receiving capability for interterminal and installation 

pipelines. 

e) Strainer on the upstream side of meters and pumps. 

f) Manual double block and bleed isolation valves where total isolation is 

required.

g) Pressure gauges on both sides of the strainer or a differential pressure 

type gauge across the strainer.

h) Compound (pressure/vacuum) gauges on the inlet side of pumps and 

pressure gauges on the outlet side of pumps.

i) Provide a combination flow control and non-surge check diaphragm 

control valve on all pumps except positive displacement types. If a 

bulk air eliminator with automatic air release head is included, provide 

a means of closing the diaphragm control valve with a solenoid pilot.

j) Provide manual isolation valves to isolate equipment for service.

k) Provide thermal relief valves around isolation and check valves to 

relieve excessive pressures caused by thermal expansion of liquid 
UFC 3-460-01

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trapped between shutoff points. See Facility Plates 023, 024, 025 and 

026. 

l) Provide a concrete housekeeping pad and, unless otherwise directed 

by Service Headquarters, a canopy to protect fixed facilities assets and 

equipment from the elements. See the “Canopies” paragraph of this 

chapter.

3-4.2 Tank Truck and Tank Car Loading Facilities

3-4.2.1 General Criteria

This chapter applies to facilities required for loading over-the-road tank truck transports 

or rail tank cars used for the bulk transfer of fuel. A typical application is the transfer by 

tank truck from a storage terminal to secondary storage, such as a filling station or a 

heating plant. In many cases, the receiving and loading facilities are combined. In 

these cases, both receiving and loading facility requirements must be addressed. This 

chapter does not include facilities for loading aviation refuelers for direct issue to 

aircraft. This process requires special design considerations as discussed in Chapter 4

of this UFC. See Facility Plates 002, 003 and 005. 

a) Determine the volume of fuel and number of tank trucks or tank cars to 

be handled by an operational analysis with assistance from Service 

Headquarters. 

b) Do not locate tank truck or tank car loading facilities closer than a 

minimum of 50 feet (15 m) from tanks, buildings, roads, overhead 

power lines, pad-mounted transformers, and property lines. Comply 

with NFPA 30 and assume that the property line is the fuel farm fence. 

Use the criteria for Class I liquids regardless of product and do not take 

a reduction for fixed fire protection. Do not locate a tank truck loading 

facility closer than 100 feet (30 m) from a railroad track (or spur) or rail 

siding for loading/off-loading of fuel.

c) Bottom loading is the only acceptable method of loading tank trucks. 

Bottom loading results in increased safety, manpower savings, quality 

control of product, and area cleanliness. At non-U.S. locations where 

only contracted top loading tank trucks are available, install a top 

loading rack with permission of Service Headquarters. In this event, 

provide future bottom loading capabilities.

d) Provide a containment area at each truck loading position consisting of 

an impermeable retention and controlled drainage system leading to a 

concrete remote spill containment system. Pave the containment area 

consisting of the islands, the spaces between islands and on each side 

of the outer islands, with concrete pitched a minimum of one percent 

toward catch basins or trench drains. Design the containment area in 

accordance with UFC 1-200-01, federal, state, and local regulations. 
UFC 3-460-01

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Do not use asphalt within a spill containment area. The maximum 

slope of any paving within a truck movement or parking area shall not 

exceed 2 percent excepting rollover curbs. If a rollover curb is 

provided, the sum of the vertical entrance and exit grades shall not 

exceed 8 percent, the horizontal length of the curb in the direction of 

truck movement shall not be less than 15 feet, and the rollover curb

shall be aligned perpendicular with direction of truck movement. 

e) At tank car loading areas, pave the containment area with concrete (or 

otherwise provide containment) for an area extending from 5 feet (1.5 

m) outside of each outer rail and extending longitudinally 15 feet (4.6 

m) each way from the center of each loading position. Slope the 

paved area to a spill containment system as described previously in 

Item (d).

f) Provide a concrete remote spill containment system for each 

containment area. Design the remote spill containment system in 

accordance with UFC 1-200-01, federal, state, and local regulations. 

Provide the remote spill containment system with capacity greater than 

either the volume of the largest tank truck or tank car compartment to 

be off-loaded or runoff from a rainfall of intensity equal to a 5-year 

expectancy, 1-hour duration storm. Provide a lockable knife gate valve 

with indicator post located outside the enclosure in an area that will be 

safely accessible during a fire. The valve shall be lockable and 

normally closed to allow for containment during fueling operations and 

which can be opened to drain the area when necessary. Tank trucks 

can be as large as 10,000 gallons (38 000 L) in capacity and tanks 

cars as large as 40,000 gallons (150 000 L). If a canopy is installed, 

reduce the sizing for rainfall, accounting for wind-blown rain. Consider 

combining the remote spill containment system with other spill 

containment systems on site, except with tank containment systems. 

However, take the level of contamination in each containment area into 

consideration.

g) Construct the drain piping between the containment area and the 

concrete remote spill containment system, and between the remote 

spill containment system and lockable knife gate valve of petroleumresistant, fire-resistant, impermeable materials. Do not use clay, 

concrete, fiberglass, or plastic piping materials.

h) Provide a canopy for protection from the elements of fixed facility 

assets and equipment per the “Canopies” paragraph of this chapter. 

i) Provide a canopy to preclude rain from the containment area when the 

requirements listed in the “Canopies” paragraph of this chapter are 

met.
UFC 3-460-01

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j) Provide separate piping, pumps, loading connections, and controls for 

each different type and grade of fuel.

k) Arrange loading rack with a row of islands with sufficient clearance 

between to allow easy access to all parts of the tank trucks when 

parked. Arrange islands and approaches in a manner that allows 

forward motion for all tank trucks at all times with ample room for 

turning. Space and arrange bottom loading islands to accommodate 

one tank truck only on the side adjacent to the tank truck’s liquid 

connections, usually the passenger side of the tank truck.

l) Provide for entrance and egress of emergency vehicles.

m) If top loading is required for tank cars (normally only when commercial 

contract leaves no other choice) and approved by Service 

Headquarters, provide a typical tank car loading rack with an elevated 

steel platform, consisting of a walkway, 4 feet (1.2 m) wide, 10.5 feet 

(3.2 m) above the top of the rails, and the full length of six tank cars. 

Ensure that the centerline of the structure is 10.5 feet (3.2 m) above 

the centerline of the tracks. Equip the platform with a counterweighted 

or spring-loaded tilting bridge to connect to the tank car dome at each 

loading station. Design so that when released from the horizontal 

position, the bridge will automatically move and lock in an upright 

position away from any part of the tank car under all weather 

conditions. Ensure conformance with UFC 1-200-01 requirements. 

Platform is not required on Air Force projects.

3-4.2.2 Tank Truck Fillstand Equipment Required

a) Provide a positive displacement or turbine meter for each tank truck fill 

connection. Protect each meter with an upstream basket strainer. 

Include temperature compensation if rack is to be point of custody 

transfer.

b) Provide fuel sampling connections for collecting test samples.

c) Provide pressure gauges on both sides of the strainer or a differential 

pressure type across the strainer.

d) Provide fusible link butterfly isolation valves as the first piece of 

equipment (in the direction of the flow) on the loading position. (Valve 

is not required on Air Force projects.)

e) Make provisions to start and stop the pumps with start and stop pump 

controls at each position. Include pump status indicator light on control 

box.
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f) Provide a solenoid operated truck loading diaphragm control valve with 

opening/closing speed control, pressure regulating, check and solenoid 

shut-off features. Interlock the solenoid with the electronic high-level 

shutoff, ground verification, and deadman control system.

g) Provide each fill position with an electronic high-level shutoff, ground 

verification, and deadman control system. The system shall be 

intrinsically safe and self-checking. Interlock the system with either the 

solenoid operated truck loading diaphragm control valve or the pump 

such that the valve cannot remain open or the pump cannot operate if 

the tank truck compartment is full, the tank truck is not grounded, or 

the deadman is released. Ensure the system is compatible with both 

electronic and fiber optic sensors with manual-keyed bypass. (May 

require a parallel effort beyond the project scope to ensure that all 

trucks using the facility have compatible connections. If facility has 

trucks that do not have fixed probes, use cane probes instead.) (This 

unit is optional on Army projects with only tactical refuelers. Contact 

the Service Headquarters for guidance.)

h) Provide emergency fuel shutoff (EFSO) pushbutton stations. For 

fillstands with multiple positions, an EFSO pushbutton station is 

required for each position and along routes of personnel ingress and 

egress between 100 and 200 feet from the fillstand. Design in such a 

manner that activation of the emergency stop will shutoff all fueling at 

that pump house or pump pad.

i) Equip liquid connections to tank trucks for bottom loading with 

drybreak couplers in accordance with API RP 1004. 

j) Refer to Chapter 2 of this UFC for guidelines on vapor collection and 

recovery or disposal systems.

k) Provide heaters and insulated, heated pipelines, as required, where 

viscous fuels are to be loaded to maintain the temperature of the fuel 

at its minimum pumping temperature.

l) Provide stainless steel loading arms (pantograph, without hoses) 

equipped with non-lubricated swivels may be used instead of hoses, if 

approved by Service Headquarters. Ensure all swivels are nonlubricated, stainless steel in-line repairable type.

m) Provide meter proving connections as described in the paragraph titled 

“Pipeline Receiving Facilities”, unless local procedure provides an 

alternative.

n) Provide relaxation tank or piping configuration with sufficient capacity 

to retain the maximum flow of the loading station for 30 seconds from 

the time the fuel leaves the last piece of filtration equipment to the fuel 
UFC 3-460-01

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reaching the loading Nozzle. Applies only to JP-5 or other fuels which 

do not have a static dissipation additive that provides a conductivity 

level greater than 50 picosiemens. 

o) Provide basket strainer upstream of meters and pumps. 

p) Provide manual isolation valves to isolate equipment for service.

q) Provide thermal relief valves around isolation and check valves to 

relieve excessive pressures caused by thermal expansion of liquid 

trapped between shutoff points. See Facility Plates 023, 024, 025 and 

026. 

r) Grounding/bonding reel (provided as an integral part of the high level 

shutoff system).

s) Provide hydraulic shock surge suppressors (if required).

3-4.2.3 Tank Car Loading Station Equipment Required

a) Provide a positive displacement or turbine meter for each tank car fill 

connection. Protect each meter with an upstream basket strainer. 

Include temperature compensation if rack is to be point of custody 

transfer.

b) Provide meter proving connections as described in the paragraph titled 

“Pipeline Receiving Facilities”, unless local procedure provides an 

alternative.

c) Provide fuel sampling connections for collecting test samples.

d) Provide pressure gauges on both sides of the strainer or a differential 

pressure type across the strainer.

e) Provide fusible link butterfly isolation valves as the first piece of 

equipment (in the direction of the flow) on the loading position. (Valve 

is not required on Air Force projects.)

f) Provide loading connections, controls, valves, etc., on one or both 

sides of the loading platform as specified by Service Headquarters. 

Load tank cars from the bottom using counterbalanced, articulated 

tank car loading assemblies.

g) Provide an electronic, intrinsically safe, portable liquid high level 

sensor with adjustable height at each loading rack. To prevent an 

overfill, interlock the sensor with the electronic high-level shutoff, 

ground verification, and deadman control system. 
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h) Provide an electronic high-level shutoff, ground verification, and 

deadman control system. The system shall be intrinsically safe and 

self-checking. Interlock the system with either the solenoid operated 

tank car loading diaphragm control valve or the pump such that the 

valve cannot remain open or the pump cannot operate if: the tank car 

is full, the tank car is not grounded, or the deadman is released. 

Provide the capability to connect the ground verification rack to the rail 

tank car frame.

i) Provide emergency fuel shutoff (EFSO) pushbutton stations. For 

fillstands with multiple positions, an EFSO pushbutton station is 

required for each position and along routes of personnel ingress and 

egress between 100 and 200 feet from the fillstand. Design in such a 

manner that activation of the emergency stop will shutoff all fueling at 

that pump house or pump pad.

j) Provide solenoid operated tank car loading diaphragm control valve 

with opening/closing speed control, pressure regulating, check, and 

solenoid shut-off features. Interlock the solenoid with the electronic 

high-level shutoff, ground verification, and deadman control system. 

k) Provide a basket strainer upstream of meters and pumps.

l) Provide manual isolation valves to isolate equipment for service.

m) Provide thermal relief valves around isolation and check valves to 

relieve excessive pressures caused by thermal expansion of liquid 

trapped between shutoff points. See Facility Plates 023, 024, 025 and 

026. 

n) Provide relaxation tank or piping configuration with sufficient capacity 

to retain the maximum flow of the loading station for 30 seconds from 

the time the fuel leaves the last piece of filtration equipment to the fuel 

reaching the loading nozzle. Applies only to JP-5 or other fuels which 

do not have a static dissipation additive that provides a conductivity 

level greater than 50 picosiemens. 

o) Provide hydraulic shock surge suppressors (if required).

3-4.3 Marine Loading Facilities

See Chapter 5 of this UFC. 

3-5 PIPING SYSTEMS

Refer to Chapter 9 of this UFC for more information regarding piping systems.

3-5.1 Product Segregation

Except as otherwise approved by Service Headquarters provide separate receiving, 

storage, and distribution systems for each product. Except as otherwise approved by 
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Service Headquarters, prevent misfueling (transferring a type of fuel other than the type 

intended) by using different size piping, valves, adaptors, nozzles, etc. 

3-6 EQUIPMENT DESCRIPTIONS

The appropriate guide specification and/or standard design provides specific information 

for equipment selection. Make provisions to drain equipment for maintenance. Provide

hardpiped drains when the equipment holds more than 5 gallons (19 L) of fuel or when 

a pipe which drains to the product recovery tank is within 12 ft (3.7 m) of the equipment.

3-6.1 Bulk Air Eliminators

Use flange-connected, steel bodied bulk air eliminator of the desired pressure and flow 

rating for the applicable service requirement. Include an automatic air release head and 

interlock the equipment with a float or solenoid-operated hydraulically operated 

diaphragm control valve. Provide discharge piping to the product recovery tank or other 

safe means of containment.

3-6.2 Meters

Provide meters with swivel mounted counter heads at truck fillstands to accommodate 

varying truck and operator positions.

3-6.2.1 Meters - Positive Displacement

Use flange-connected, cast steel bodied positive displacement meters of the 

appropriate pressure and flow rating to meet applicable service requirements. Ensure 

meter has case drain and register. Provide temperature compensation and adjustable 

calibration capabilities where there is custody transfer. Ensure meter accessories are 

compatible with either the mechanical or electronic support equipment selected. 

Provide an accuracy of plus or minus 0.5 percent when used for custody transfer. 

Consult the appropriate Service Headquarters for requirements for the meter to 

communicate to a remote location or equipment. Consider the use of a card-operated 

or key-operated data acquisition system. Refer to “Card and Key Locks” under 

“Controls” paragraph of this chapter.

3-6.2.2 Meters – Turbine

Use flange-connected steel bodied turbine meters of the appropriate pressure and flow 

rating to meet applicable service requirements. Provide a flow straightener before 

turbine meters or provide a straight length of pipe at a minimum of ten pipe diameters 

upstream and five pipe diameters downstream of all turbine meters, or as required by 

manufacturer. Ensure meter has case drain and register. Provide temperature

compensation and adjustable calibration capabilities where there is custody transfer. 

Provide an accuracy of plus or minus 0.5 percent when used for custody transfer. 

Ensure all supporting equipment for meter is compatible with the turbine meter selected. 

Consult the appropriate Service Headquarters for requirements for the meter to 

communicate to a remote location or equipment. Consider the use of a card-operated 

or key-operated data acquisition system. Refer to “Card and Key Locks” under 

“Controls” paragraph of this chapter.
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3-6.2.3 Meters – Orifice

Use this type of meter only where custody transfer or accounting/inventory control is not 

required. Provide with flange connections. Provide a flow straightener before orifice 

meters or provide a straight length of pipe at a minimum of ten pipe diameters upstream 

and five pipe diameters downstream of all orifice meters, or as required by 

manufacturer.

3-6.3 Pressure or Pressure/Vacuum Gauges

Use liquid-filled gauges of range and dial size, as necessary, but not less than 0 to 160 

psig (0 to 1100 kPa) pressure range and 4-inch (100 mm) diameter dial. Gauges shall

be all stainless steel construction, with black graduations on a white face. For extreme 

temperature environments, consult Service Headquarters for direction on the possible 

use of air-filled gauges. For locations where the temperature is less than -40 degrees F

(-40 degrees C), use appropriate gauge liquid that will not freeze to prevent damaging 

the gauge.

a) Consider the location, year-round weather conditions, and service 

requirements for the type of liquid filling to be used.

b) Gauge liquids and service ranges.

Liquid Range

Glycerin 0 °F to 400 °F

(-18 °C to 204 °C)

Silicone -40 °F to 600 °F

(-40 °C to 316 °C) 

c) Provide a lever handle gauge cock and pressure snubber in each 

pressure gauge connection.

d) Provide indicating and recording pressure gauges on suction and 

discharge lines for interterminal pipeline pumping stations and on the 

incoming line at the delivery terminal of each such pipeline, if required 

by Service Headquarters. 

e) Pressure gauges shall be installed so that they are testable without 

removing them from the piping.

3-6.4 Strainers

Require a strainer to protect centrifugal pumps, unless it precludes meeting the net 

positive suction head of the pump. Whether or not strainers are installed on the suction 

side of centrifugal pumps, require a spool piece so that temporary strainers can be 

installed during startup of the system. Strainers are required on the suction side of all 

pumps, meters, and receipt filtration. Also:

a) Use flanged basket strainers constructed of steel and fitted with 

removable baskets of fine Monel metal or stainless steel mesh with 
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large mesh reinforcements. Provide quick opening, single screw type 

with drain connection in bottom.

b) Provide a fine screen mesh as follows:

Mesh Size of Opening

Pump suctions (Centrifugal) 7 0.108 inch (2.74 mm)

Pump suctions (Positive

Displacement) 40 0.016 inch (0.40 mm)

Receipt Filtration 40 0.016 inch (0.40 mm)

Meter inlets (unless downstream 

of a filter/separator) 40 0.016 inch (0.40 mm)

c) In all cases, ensure the effective screen area is not less than three 

times the cross sectional area of the pipe.

d) Provide pressure gauges on both sides of the strainer or a differential 

type gauge across the strainer.

3-6.5 Surge Suppressors

Every effort should be made to control hydraulic surge or shock to acceptable limits by 

the design of the piping system rather than by the use of surge suppressors. Where 

this is not possible or becomes extremely impractical, surge suppressor(s) may be 

incorporated. Use the diaphragm or bladder type equipped with a top-mounted liquidfilled pressure gauge, wafer-style check valve at the bottom, drain above the check 

valve, and isolation valve. Provide a needle valve around the check valve to permit 

controlled bleed back of the surge suppresser without rebounding. Locate surge 

suppressors as close as possible to the point of shutoff that is expected to cause the 

shock. Surge suppressors can reduce shock pressure but will not eliminate it entirely. 

The preferred solution to hydraulic shock is conservative piping design, use of loops, 

and slow-closing valves. Surge suppressors are strictly a last resort solution and 

require the approval of Service Headquarters prior to designing into a system.

3-6.6 Pumps

3-6.6.1 Design Requirements

Design pumps to deliver the full range of operating conditions anticipated at any facility 

with flow rates as presented in Chapter 2 of this UFC. Ensure pumps develop sufficient 

head to overcome the friction and static head losses in the system at the rated flow. 

Consider the specific gravity, temperature, viscosity, vapor pressure, corrosive, and 

solvent properties of the fuel. If a range is given for the specific gravity, etc., in 

paragraph 2.3, use the larger value for the purpose of calculations. For any single 

grade of fuel, connect pumps in parallel. Select according to the type most suitable for 

the particular application. Do not use positive displacement or reciprocating pumps for 

product issue or pipeline transfer. Provide enough pumps to allow the system to 

operate at full capacity with the largest pump out-of-service. 
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3-6.6.2 Centrifugal Pumps

Use API Std 610 centrifugal pumps to pump from aboveground tanks with continuously 

flooded suctions.

3-6.6.3 Vertical Turbine Pumps

Use API Std 610 vertical turbine pumps to pump from underground tanks. Do not use 

horizontal transfer pumps in a pit alongside the underground tank as an alternative.

3-6.6.4 Rotary Pumps

Use sliding vane positive displacement pumps or self-priming centrifugal pumps for 

applications such as stripping pipelines or similar service where the pump may 

frequently lose its prime. For these pumps, provide a pressure relief valve located on 

the discharge side of the pumps. A variable speed motor can be used on positive 

displacement pumps to gradually bring the pump to normal operating speed. 

Note: On positive displacement pumps the pressure relief valves shall be considered 

safety relief valves, not operating valves (valves that modulate on a normal basis to 

maintain a set pressure). Use of the relief valve to modulate the pump discharge 

pressure voids the pump warranty. 

3-6.6.5 Drivers

Drive permanently installed pumps by an electric motor which is properly classified in 

accordance with NFPA 70. Size drivers to be non-overloading at any point on the 

curve. Provide anti-reversing rachets on all vertical turbine pump motors.

3-6.6.6 Materials of Construction

Use carbon steel or nodular iron casings and components. Refer to Chapter 4 of this 

UFC for aviation turbine fuels requirements.

3-6.6.7 Installation

Mount permanently installed pumps on substantial foundations of reinforced concrete 

designed in accordance with Hydraulic Institute Standards. 

3-6.7 Valves

3-6.7.1 Materials of Construction – General Service

Require valves to have carbon steel bodies and bonnets except for aviation turbine 

fuels (see below). Valves in general service may be internal nickel plated, or internal 

epoxy coated. Do not allow valves with aluminum, cast iron, or bronze materials. Use 

only API fire-safe valves.

3-6.7.2 Materials of Construction – Aviation Turbine Fuel Service

Valve materials in contact with aviation turbine fuel shall either be stainless steel,

chrome plated carbon steel, or electroless nickel plated carbon steel. Do not allow zinc, 

zinc-coated, copper, or copper bearing materials in contact with the fuel. Do not allow 

internally epoxy-coated valves. 
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Require manual valves in aviation turbine fuel systems to have stainless steel bodies 

and bonnets. Carbon steel bodied valves are permitted provided they are internally 

plated with nickel plating. Do not allow aluminum, cast iron, or bronze bodied valves. 

Use only API fire-safe valves.

3-6.7.3 Isolation Valve Types

a) Double Block and Bleed Isolation Valves: 

(1) Use these for separation of product services, on tank shell 

connections, when piping goes above or below ground, between 

pier and tank storage, and other locations critical to pressuretesting of piping.

(2) Plug Valves (Double Block and Bleed): Use double-seated, 

tapered lift, lockable, plug type valves with a body bleed between 

the seats (double block and bleed). Valves shall be designed so 

that if the synthetic seating material is burned out in a fire, a 

metal-to-metal seat will remain to affect closure and comply with 

API Std 607. Lubricated plug valves are not allowed. Include 

integral body cavity thermal relief valve. 

(3) Ball Valves (Double Block and Bleed): Use double-seated, 

trunion mounted, lockable, ball type valves with a body bleed 

between the seats (double block and bleed). These will be very 

rarely used but are acceptable as an alternative to double block 

and bleed plug valves in applications where the valve is operated 

very infrequently. An example is isolation valve pits where they 

are only closed to perform pressure testing of piping. Valves 

shall be designed so that if the synthetic seating material is 

burned out in a fire, a metal-to-metal seat will remain to affect 

closure and comply with API Std 607. Include integral body 

cavity thermal relief valve. 

(4) Gate Valves (Double Block and Bleed): Use double-seated, 

lockable, gate type valves with a body bleed between the seats 

(double block and bleed). These will be very rarely used but are 

acceptable as an alternative to double block and bleed plug 

valves and double block and bleed ball valves only when other 

double block and bleed valves will not physically fit. Valves shall 

be designed so that if the synthetic seating material is burned out 

in a fire, a metal-to-metal seat will remain to affect closure and 

comply with API Std 607. Single seated gate valves are not 

allowed. Include integral body cavity thermal relief valve. 

b) Quick Opening/Frequent Opening Isolation Valves: 
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(1) Use these for less critical applications where double block and 

bleed shutoff is not required.

(2) Ball Valves: Ball type, lockable, valves designed so that if the 

synthetic seating material is burned out in a fire, a metal-to-metal 

seat will remain to affect closure and comply with API Std 607. 

Use Teflon or Viton synthetic seals or seating material. Use full 

port ball valves where line pigging is required or if within ten pipe 

diameters upstream and/or five pipe diameters downstream of a 

flow or pressure control valve, or a flow-sensing device such as 

a venturi. Valves should comply with API Std 608. 

(3) Butterfly Valves: High-performance wafer trunion butterfly type 

valves designed so that if the synthetic seating material is 

burned out in a fire, a metal-to-metal seat will remain to affect

closure and comply with API Std 607. Use Teflon or Viton 

synthetic seals or seating material. Use valves of highperformance type with eccentric disc shaft and clamping action 

for bubble-tight shutoff. Provide only at inlet to truck fillstand and 

on supply and return risers at aircraft direct fueling stations with 

fusible link set to release at 165 degrees F (74 degrees C). 

These valves are not required nor permitted on Air Force 

projects.

c) Use full port valves with exact same diameter of the pipe when line 

pigging is required.

3-6.7.4 Isolation Valve Operators

Manually operate valves not specified for remote, automatic, or emergency operation. 

Use geared operators for ball and double block and bleed plug valves larger than 6 

inches (150 mm). Double block and bleed gate, ball, and double block and bleed valves

specified for remote, automatic, or emergency service may have electric motor 

operators, if approved by Service Headquarters. Provide locking tabs on isolation 

valves to allow padlock to be used to lock out the valves during maintenance. Provide 

chain operators on valves which are located 72 inches (1800 mm) or higher above 

grade.

3-6.7.5 Isolation Valve Locations

Provide isolation valves in piping systems to control flow and to permit isolation of 

equipment for maintenance or repair. Provide additional valves at locations necessary 

to conduct a valid hydrostatic test. Require manually operated valves, except where 

motor operators are specifically authorized by applicable standard drawings or technical 

specifications. Use double block and bleed type isolation valves for separation of 

product services, on tank shell connections (ASTs over 12,000 gallons only), when 

piping goes above or below ground, between pier and tank storage, and other locations 

critical to periodic pressure-testing of piping. Quick opening/frequent opening type 

isolation valves may be used for less critical applications where double block and bleed
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shutoff is not required. As a minimum requirement, provide isolation valves at the 

following locations:

a) Where piping goes underground or comes aboveground and requires 

periodic pressure testing.

b) At all subsurface and aboveground piping connections to storage 

tanks. 

c) On each branch line at the point of connection to the main product 

pipeline or header.

d) On the product pipeline or header just before the line leaves a pumping 

station.

e) On the suction side and discharge side of each pumping unit, except 

the suction side of vertical centrifugal pumps installed in underground 

tanks. 

f) On the upstream and downstream side of each line blind at 

connections to cross country pipelines.

g) On the inlet and outlet connection of each line strainer, filter/separator, 

meter, diaphragm control valve, and other equipment that requires 

periodic servicing. One inlet valve and one outlet valve may be used 

to isolate more than one piece of adjacent equipment which are 

connected in series.

h) On each main distribution pipeline immediately downstream of the 

branch connection to each existing or future operating storage facility 

served by the pipeline.

i) On the aboveground piping at each tank car or tank truck off-loading 

connection, and at each inlet to the gravity drop tank. 

j) On the aboveground piping at each tank car and tank truck loading 

connection.

k) At critical roadway, runway and taxiway crossings, consider isolation 

valves on both sides of runway/taxiway to facilitate hydrostatic testing

and isolation.

3-6.7.6 Isolation Valve Pits

Provide Fiberglass or concrete pits with a rolling or hinged cover designed in 

accordance with the Air Force Standard Design AW 78-24-28 for all isolation valves 

installed in non-traffic areas on underground fuel systems. Design valve pits and valve 

operators so that the valves can be operated by personnel, without confined space 

entry.
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3-6.8 Other Valves (Except Diaphragm Control Valves)

3-6.8.1 Check Valves

Use check valves to prevent backflow through pumps, branch lines, meters, or other 

locations where runback or reverse flow must be avoided. Check valves may be of the 

swing disk, globe, dual plate hinged disk, spring-loaded poppet, ball, or diaphragmactuated types. Use checks of soft-seated non-slamming type with renewable seats 

and disks. Ensure check valves conform to API Spec 6D. Use non-surge check

diaphragm control valves with flow control feature on the discharge of all pumps. When 

using non-surge check diaphragm control valves on pump discharge, consider the use 

of a spring type wafer check before the diaphragm valve to prevent sudden flow 

reversals during shutdown from passing back thru the pump before the diaphragm

control valve diaphragm chamber is filled and reacts by closing the valve. 

3-6.8.2 Thermal Relief 

Provide thermal relief valves around isolation and check valves to relieve excessive 

pressures caused by thermal expansion of liquid trapped between shutoff points. See 

Facility Plates 023, 024, 025 and 026. 

3-6.9 Diaphragm Control Valves

Hydraulically operated, single-seated, globe type, diaphragm actuated control valves 

are used extensively in fueling systems as control valves. These valves consist of a 

main valve and a pilot control system. The main valve consists of a body, diaphragm, 

and cover and is operated by varying the amount of pressure above the diaphragm. 

Since the chamber above the diaphragm exposes a greater area of the diaphragm to 

chamber pressure than the area of the disc exposed to line pressure, an equal pressure 

in the chamber and pipeline results in a greater force being applied to the top of the 

disc. This forces the disc against the seat, thus closing the valve. By selecting the 

proper pilot control system, these valves can be used in numerous ways to control flow, 

pressure, and level within fueling systems.

3-6.9.1 Open/Close Operation

This is the most basic function of hydraulically operated diaphragm control valves. The 

operation is accomplished by applying pressure above the diaphragm to close the valve 

and relieve that pressure to allow line pressure to open the valve. The pilot trim used to 

perform this operation is a three-way valve which can be controlled by a solenoid, hand, 

pressure, pressure differential, or a float.

3-6.9.2 Throttling Operation

This is the other main method of controlling the hydraulically operated diaphragm 

control valve. In this case, the valve modulates to any degree of opening, in response 

to changes in the throttling control. The throttling control reacts to a pressure or a 

pressure differential across the main valve or a pressure differential across an orifice 

plate to regulate the position of the disc in the main valve. For proper operation these 

valves should be installed with straight pipe on both sides of the valve. Ten pipe 

diameters on the upstream side and five diameters on the downstream side is sufficient; 

provide full port manual isolation valves if they are placed within these limits.
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3-6.9.3 Check Valve Function

This is a unique function of a control valve. In this case, the main valve outlet pressure 

is connected to the diaphragm cover. Therefore, if the downstream outlet pressure 

exceeds the inlet pressure, which normally holds the valve open, the valve will close 

and prevent backflow. Note: In order for the valve to close it must backflow, sometimes 

for a substantial amount of time. Consider putting a regular check valve in series with 

this valve in cases where this is a concern.

3-6.9.4 Remote Operations

Hydraulically operated diaphragm control valves can be operated remotely. This is 

accomplished by installing tubing from the point of pressure sensing to the valve or by 

using remote-controlled solenoids within the trim.

3-6.9.5 Materials of Construction

Use stainless steel pilot control valves and stainless steel tubing. Use bodies, bonnets, 

and covers made stainless steel, internally plated (chrome) steel, or internally plated 

(nickel) nodular iron. Provide Viton or Buna-N diaphragm and disc ring. Enclose all 

electrical apparatus according to classification of the area in which they are installed. 

Provide a means to wire seal all adjustable pilots. Do not use aluminum valves.

3-6.9.6 Applications

For fueling systems, use hydraulically operated diaphragm control valves in the 

following applications (also refer to specific chapters for applications):

a) Water slug shutoff. 

b) Rate of flow control.

c) Pressure reduction.

d) Pressure relief.

e) Liquid level control.

f) Non-surge check control.

g) Deadman control. 

h) Electrical block control.

3-6.9.7 Combinations

A combination of these controls is also possible. A typical use of these controls is on a 

filter/separator for water slug shutoff and rate of flow control.

3-6.10 Thermometers

Provide thermometers in Burner Fuel No. 5 and No. 6 distribution piping systems at 

each loading and receiving point and on the inlet and outlet of each heater.
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3-6.11 Fuel Hoses

Use sizes as required for design flow rates. For hose flanges and nipples, use carbon 

steel or brass, except at aviation turbine fuel issue points use brass, stainless steel, or 

aluminum where metal parts contact the fuel.

3-6.11.1 Loading Fuel Hoses

Provide pressurized loading hoses and connections complying with EI Std 1529. 

3-6.11.2 Off-Loading Fuel Hoses 

Provide lightweight, flexible, non-pressurized off-loading hoses constructed of nitrile 

rubber, rigid polyvinyl chloride (PVC) helix, synthetic braiding, smooth bore, and 

corrugated outer diameter. Provide non-pressurized hoses with a 65 psi (450 kPa) 

rating at 72 degrees F (22 degrees C) and 27 in Hg (90 kPa) vacuum rating. 

3-7 CONTROLS

3-7.1 Design Requirements

Automatic controls at any facility may include temperature, pressure, fuel level and 

pump controls, automatic flow controls, alarm and limit switches, motor operated 

isolation valves, solenoid pilot actuated diaphragm control, and remote system condition 

indicators. Other forms of automatic controls are remote meter indication, electronic 

access control, data logging, and application of computer techniques. Base the 

selection of advanced automation and telemetry systems on a study of the particular 

application with consideration of possible economic justification, operational, and 

security requirements.

3-7.2 Flow Controls

Where it is possible to achieve flow rates which exceed equipment ratings, provide an 

adjustable flow control valve on the outlet connection of each meter or filter/separator. 

Use a diaphragm control valve controlled by the pressure differential across an orifice or 

a venturi in the main line. Where necessary, provide remote-operated valves on 

storage tank inlet and outlet lines, suction and discharge of transfer pumps, and transfer 

lines at fuel piers and other locations.

3-7.3 Pump Controls 

Operation of pump suction and discharge valves may be a part of the automatic 

sequence for the starting of a centrifugal pump and for shutting it down, remotely, 

locally, or by a protective shutdown device. Remote-operated valves on the discharge 

side of the pump can be either motor-operated or the solenoid pilot-type, hydraulically 

operated diaphragm control valves. Remote control valves on the suction side of the 

pump can be motor-operated valves only. Equip these valves with green and red (open 

and closed) indicating lights at their pushbutton control locations. Consider the use of 

PLCs on more complicated systems.

3-7.3.1 All Pumps 

Provide the following controls:
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a) A keyed hand/auto button at each pump and a keyed hand-off-auto 

switch at the motor starter for each remotely operated pump. Both 

devices will use the same key.

b) Indicator lights at the control station to give positive indications both 

when a pump is operating and when it is not energized. Use the 

"push-to-test" type.

c) A signal light or alarm to indicate pump failure when a pump is 

controlled automatically.

d) Reduced voltage starting if required by electric utility supplier or in all 

cases for pump motors greater than 50 horsepower (37 kW) and all 

vertical pumps.

e) Emergency fuel shut-off (EFSO) pushbutton stations, between 100 and 

200 feet from the pump in the expected ingress and egress direction, 

with maintained contacts. Provide additional EFSO pushbutton 

stations at the point of fuel delivery or receipt (fillstands, piers, tanks, 

etc.) using the same spacing and location requirements.

3-7.3.2 Multi-Function Pumps

Multi-function pumps are typically used at small facilities and are designed and 

arranged to be able to perform different functions such as fuel loading, off-loading, or 

transfer depending on how valves are aligned. Provide each function with the control 

system requirements for each function described elsewhere in this chapter. For each 

multi-task pump provide a manual selector switch to choose which set of control and set 

points the pump is to "look at" when performing a particular function. 

3-7.3.3 Transfer Pumps

Transfer pumps are used to supply fuel to a tank truck loading facility, tank car loading 

facility, or transfer fuel from one place on the installation to another (e.g., bulk storage 

tank facility to operating storage tank). If these pumps exceed 150 horsepower (112 

kW), comply with the paragraph titled “Pipeline Pumps” in this Chapter. In addition to 

requirements in the paragraph titled “Pipeline Pumps” in this Chapter, provide transfer 

pumps with push button start/stop stations. Where these pumps are used for truck 

and/or car loading, provide push button controls adjacent to the pumps and at each 

loading station. Use programmable logic controllers (PLC) where multiple pumps 

supply header loading multiple trucks or cars to obtain desired flow rate to each loading 

station.

3-7.3.4 Pipeline Pumps

For pumps over 150 horsepower (112 kW), provide protective shutdown devices with 

alarm at central supervisory control station in the event of the following:

a) High pump case temperature due to blocked discharge.

b) Excessive pump vibration.
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c) Mechanical seal or packing gland failure.

d) High discharge pressure or loss of discharge pressure.

e) Excessive motor vibration.

f) High motor winding temperature.

g) Electrical interlocks which will prevent starting a pump if certain key 

valve settings are not correct and which will cause a pump shutdown if 

a key valve setting is changed.

h) Loss of pump suction pressure.

i) High bearing temperature and/or loss of cooling water flow.

3-7.3.5 Temperature Controls 

Provide temperature controls at all fuel oil heaters to control the outlet oil temperature 

within safe limits. Provide a sensing element in the fuel outlet line which activates a 

thermostatic valve in the heating medium supply connection to the heater. Use a selfactuating control valve that requires no external power for closure. Use a manually 

adjustable set point for each temperature variable over the desired temperature range. 

Provide a bypass around the control valve with a V-port globe or ball valve for manual 

operation.

3-7.3.6 Card and Key Locks

Consider the possible economic and operational advantages of using an electronic card 

or key system which permits 24-hour unmanned operation of the facility. These types of 

systems are comprised of a card/key reader which is located near the service pump. 

The reader is activated by a card or key and accumulates issues and customer data 

which is downloaded to a central computer on a periodic basis. Activities with 

capitalized fuel, that is petroleum product owned by Defense Logistics Agency (DLA)/ 

DESC, are eligible for projects to install automated card/key lock systems. Activities 

with capitalized fuel report inventories of these products to DESC through a system 

called Business Systems Modernization - Energy (BSM-E). Automated systems to 

control capitalized inventories must be able to interface with the BSM-E. These types of 

automated systems are managed under the automated fuel service station (AFSS) 

program by DESC. It should be noted that AFSS equipment is used to control issues of 

product and is not an automated tank gauging system. Further information on AFSS 

systems and funding programs may be obtained by contacting DESC-FE.

3-8 CANOPIES

3-8.1 Canopies to Protect Fixed Assets

Unless otherwise directed by Service Headquarters, provide a canopy to protect fixed 

facility assets and equipment from the elements. Fixed facilities and equipment include 

but are not limited to: pump pads, filtration pads, meter pads, isolation valve pads, tank 

truck and tank-car off-loading and loading equipment pads, control panels, electrical 
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panels, and motor control centers (MCCs). Ensure structural design is in accordance 

with UFC 1-200-01 and UFC 3-301-01 . 

3-8.2 Canopies to Reduce Stormwater

Do not provide a canopy to preclude rain from reaching the containment area unless it 

is required by federal, state, or local regulations; or it is economically justified by 

reducing the size of the concrete remote spill containment or spill treatment system; or if 

directed by Service Headquarters. At a canopy over a tank truck or tank car loading 

and off-loading containment area, ensure that the underside of the canopy is high 

enough to provide operator head room when walking on top of the truck or car. Ensure 

structural design is in accordance with UFC 1-200-01 and UFC 3-301-01. 

3-9 PRODUCT RECOVERY SYSTEMS

Provide a product recovery system to collect and store usable aviation turbine fuel that 

would otherwise become waste from operational or maintenance activities. Consider a 

product recovery system for other products. See Chapter 8 of this UFC for product 

recovery systems.

3-10 FUEL ADDITIVES 

If directed by DESC, provide bulk storage facilities which store aviation turbine fuels 

with the equipment to inject fuel additives. This will require proportional injectors, 

storage of additives, and capability of recirculating tanks through piping with injectors. If 

the additives have a corrosive characteristic, construct the system, including storage 

tanks, tank appurtenances, pumps if required, piping and associated fittings, valves, 

and injector assemblies of stainless steel components.
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CHAPTER 4 - AIRCRAFT FUELING FACILITIES

4-1 INTRODUCTION

This chapter provides guidance for the design of aircraft fueling facilities, including 

operating storage tanks and those components normally located within a typical 

compound. These components include pipeline receiving facilities, tank truck and tank 

car receiving facilities, refueler truck fillstands, type III, IV, and V aircraft direct fueling 

systems, and associated piping and equipment. Fuel storage tanks are discussed in 

Chapter 8 and piping systems in Chapter 9 of this UFC. Systems used to receive fuels 

from barges and ships are discussed in Chapter 5. Pipelines that transport fuel from off

base and pipelines between bulk tanks and operating storage tanks are discussed in 

Chapter 6 of this UFC.

Note: If aviation fuel can be pumped directly from a tank into an aircraft, aircraft direct 

fueling system or a refueler, treat the tank as an operating storage tank regardless of 

size and location and meet the applicable requirements for aviation turbine fuel 

operating tanks. The exception is bulk storage tanks that are configured to fill refuelers 

on an emergency basis only.

4-1.1 Function

Aircraft fueling facilities, as discussed in this chapter, are designed for ground fueling of 

fixed and rotary wing aircraft. Two methods are used for refueling aircraft: refueler

trucks and aircraft direct fueling systems (e.g., hydrant system). The preferred method 

of fueling used at most Navy, Marine Corps, and Army small aircraft bases is by refueler

trucks. For Air Force transport, tanker, cargo, bomber, and other large aircraft, the 

preferred method of fueling is by hydrant system where the aircraft are fueled on the 

apron in their parked positions. Where operational/mission requirements dictate a quick 

return to the air, small-frame aircraft, both fixed and rotary wing, are refueled with the 

engines running via aircraft direct fueling systems under a "gas and go" or hot pit 

refueling concept. Install aircraft direct fueling systems only when specifically 

authorized by Service Headquarters.

4-1.2 Aviation Turbine Fuels

The fuels covered in this chapter are JP-4, JP-5, JP-8, JPTS, Jet A, and Jet A-1. 

Because of the critical nature of the end use of the fuel, protection of fuel quality, 

dependability of the system, and safety are very important. Refer to Chapter 2 of this 

UFC for information on fuel properties.

4-1.3 Special Precautions for Aviation Turbine Fuel Quality

Take extra care to prevent the contamination of aviation turbine fuels by dirt, water, and 

other fuels. For additional information, refer to Chapter 2 of this UFC. Aircraft fueling 

system must be designed with capability to generate sufficient turbulent flow to flush 

sediment and condensed water from all portions of piping systems. Refer to Chapter 9

of this UFC for fuel velocity criteria.
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4-2 GENERAL REQUIREMENTS

Chapter 2, General Design Information, contains information on fueling facilities. Do not 

begin the design on any fueling system without first becoming completely familiar with 

Chapters 2 and 9 of this UFC and with the airfield clearance requirements found in UFC 

3-260-02. 

4-3 RECEIVING FACILITIES

Fuel deliveries to a military aviation activity are normally made by tank truck, railroad 

tank car, barge, or pipeline. A secondary method of delivery is normally required. 

Service Headquarters, with concurrence from the DESC, will determine the appropriate 

type of delivery method based on mission requirements and an economic analysis.

4-3.1 Pipeline Receiving Facilities

4-3.1.1 General Criteria

Petroleum fuels may be supplied to aviation turbine fuel storage tanks by interterminal 

pipelines or installation pipelines. Interterminal pipelines may be dedicated to serving 

the particular facility or may be commercial pipelines handling a number of types or 

grades of fuel for more than one user. Installation pipelines will normally be a pipe from 

the bulk facility to the aircraft fueling facility. Provide for separate receiving and 

distribution piping for each grade of aviation turbine fuel unless otherwise approved by 

Service Headquarters. Exercise extreme care to avoid designing a system that could 

create damaging surges in the pipeline created by quick closing valves.

4-3.1.2 Equipment Required

a) Provide pressure-regulating diaphragm control valves to reduce 

pipeline pressures to the design pressure of the facility’s piping and 

equipment. Provide a manual isolation valve at both the upstream and 

downstream side of each diaphragm control valve. Prior to designing 

any features into the system which might affect the flow from a 

pipeline, contact the operator of the pipeline to ascertain the current 

operating conditions, evaluate the use of diaphragm control valves, 

conduct a surge analysis of the pipeline, and determine whether the 

use of diaphragm control valves is appropriate.

b) Provide a meter at the receiving end of the line to measure quantities 

of fuel received. Turbine-type meters are commonly used for pipeline 

receipt. However, positive displacement meters are acceptable if 

available at the required flow rate. Consider the use of alternative 

meter technologies such as ultrasonic meters. Compensate for fuel 

temperature at the point of custody transfer. Provide a basket strainer 

on the upstream side of the meter and connections for proving the 

meter with a portable prover. A meter prover connection consists of a 

manual isolation valve in the main pipeline with a tee on both the 

upstream and downstream sides of the valve. The branch of each of 
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the tees has a manual isolation valve and a hose connection. The 

master meter can be attached to the hose connections.

c) Provide a means for sampling each pipeline product at a breakout 

manifold.

d) Provide provisions for a contractor to bolt pig launchers and receivers 

to the system for pigging. Arrange pig receiving connections to avoid 

introducing pipeline sludge and sediment into the tanks. Pig launching 

and receiving connections are required for interterminal (cross-country) 

and installation (as described in Chapter 6 of this UFC) underground 

pipelines.

e) Provide an interface tank to receive mixed fuels at the beginning and 

ending of a shipment unless the commercial pipeline company can 

provide this service satisfactorily.

f) Provide a breakout tank only if pipeline flow cannot be stopped due to 

pipeline operational requirements. Provide valves to divert the flow of 

fuel from the pipeline to the breakout tank in the event fuel transfer is 

blocked by a manual or automatic valve within the fuel facility system 

such that the fuel facility system would be overpressurized from 

transient surge or high pressure from deadheading a pipeline supply 

pump. Provide appropriate breakout tank overfill alarms and alarm 

breakout operation so fuel facility operators can take necessary steps 

to stop pipeline flow. Provide means of transferring fuel out of 

breakout tank back to fuel systems after a breakout event. Conduct a 

thorough review with the pipeline operator and perform a transient 

surge analysis to determine if surge pressure reduction methods are 

required to avoid damage to the pipeline.

g) Provide means of inbound filtration for all products. The selection of 

filtration depends on anticipated impurities, the source of fuel, and the 

shipping methods. Avoid the use of water slug shutoff diaphragm 

control valves or other rapid-closing valves on pipeline receipt facilities. 

See the “Special In-Bound Filtration” paragraph and Table 4-1 of this 

Chapter of the UFC for details. 

h) Provide manual isolation valves to isolate equipment for service.

i) Provide basket strainers upstream of meters and filtration.

j) Provide thermal relief valves around isolation and check valves to 

relieve excessive pressures caused by thermal expansion of liquid 

trapped between shutoff points. See Facility Plates 023, 024, 025 and 

026. 
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k) Provide a concrete housekeeping pad and, unless otherwise directed 

by Service Headquarters, a canopy to protect fixed facilities assets and 

equipment from the elements. See the “Canopies” paragraph of this 

chapter.

4-3.2 Tank Truck and Tank Car Off-Loading Facilities

4-3.2.1 General Criteria

Fuel system operating tanks may be supplied with fuel by tank truck or tank car or both. 

At facilities with pipeline or water transport as their principal supply source, provide tank 

truck or tank car deliveries as a secondary supply source. Tank truck deliveries are the 

most common method. However, special transportation considerations or changing 

circumstances may make the use of rail facilities desirable. Therefore, at an activity 

with railroad service, arrange a tank truck receiving facility so that the system can be 

easily and economically extended to the existing rail spur. See Facility Plate 002. 

a) The preferred off-loading method is into a drop tank off-loading system. 

See Facility Plate 003. 

b) Provide a packaged off-loading system when a drop tank type offloading system is not practical for off-loading tank trucks or tank cars 

due to environmental concerns, site limitations, or cost considerations, 

and/or when directed by Service Headquarters. See Facility Plate 004. 

c) Provide a direct off-loading system when only an occasional tank truck 

requires off-loading and when directed by Service Headquarters. See 

Facility Plate 005. 

d) Do not locate tank truck or tank car receiving facilities closer than 50 

feet (15 m) from tanks, buildings, roads, overhead power lines, padmounted transformers, and property lines. Comply with NFPA 30 and 

assume that the property line is the fuel farm fence. Use the criteria for 

Class I liquids regardless of product and do not take a reduction for 

fixed fire protection.

e) Provide an adequate number (minimum two) of positions to off-load the 

daily fuel requirements of the facility in an 8-hour period without 

causing detention or demurrage of delivery conveyances.

f) Provide separate off-loading connections for each type of fuel to be 

handled. To facilitate the use of tank trucks with multiple independent 

compartments, provide a hose manifold with a minimum of two 

connections per tank truck. A manifold with hose connections equal to 

the number of truck compartments is recommended for quick 

turnaround. If less than five connections are provided, provide a blind 

flange on the end of the manifold to accommodate additional 

connections.
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g) Provide a containment area at each truck off-loading position

consisting of an impermeable retention and controlled drainage system 

leading to a concrete remote spill containment system. Pave the 

containment area consisting of the islands, the spaces between islands

and on each side of the outer islands, with concrete pitched a minimum 

of one percent toward catch basins or trench drains. Design the 

containment area in accordance with UFC 1-200-01, federal, state and 

local regulations. Do not use asphalt within a spill containment area. 

The maximum slope of any paving within a truck movement or parking 

area shall not exceed 2 percent excepting rollover curbs. If a rollover 

curb is provided, the sum of the vertical entrance and exit grades shall 

not exceed 8 percent, the horizontal length of the curb in the direction 

of truck movement shall not be less than 15 feet, and the rollover curb 

shall be aligned perpendicular with direction of truck movement.

h) At tank car off-loading areas, pave the containment area with concrete 

(or otherwise provide containment) for an area extending from 5 feet 

(1.5 m) outside of each outer rail and extending longitudinally 15 feet 

(4.6 m) each way from the center of each loading position. Slope the 

paved area to a spill containment system as described previously in 

item (g).

i) Provide a concrete remote spill containment system for each 

containment area. Design the remote spill containment system in 

accordance with UFC 1-200-01, federal, state, and local regulations. 

Provide the remote spill containment system with capacity greater than 

either the volume of the largest tank truck or tank car compartment to 

be off-loaded or the runoff from a rainfall of intensity equal to a 5-year 

expectancy for a 1-hour duration. Provide a lockable knife gate valve 

with indicator post located outside the enclosure in an area that will be 

safely accessible during a fire. The valve shall be lockable and 

normally closed to allow for containment during fueling operations and 

which can be opened to drain area when necessary. Tank trucks can 

be as large as 10,000 gallons (38 000 L) in capacity and tank cars as 

large as 40,000 gallons (151 000 L). If a canopy is installed, reduce 

the sizing for rainfall, accounting only for wind-blown rain. Consider 

combining the remote spill containment system with other spill 

containment systems on-site, except with tank containment systems. 

However, take the level of contamination in each containment area into 

consideration.

j) Construct the drain piping between the containment area and the 

remote spill containment system, and between the remote spill 

containment system and lockable knife gate valve of petroleumresistant, fire-resistant, impermeable materials. Do not use clay, 

concrete, fiberglass, or plastic piping materials.
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k) For off-loading tank trucks, arrange the flow of traffic to permit 

continuous forward movement of trucks at all times. Commercial tank 

trucks off-load on the passenger side.

l) To determine the number of connections needed for off-loading tank 

cars, consult with Service Headquarters and consider minimizing tank 

car movements, tank car shipping schedules, conveyance turn-around 

times, local rail switching capabilities, and quantity of fuel needed for 

one day’s fuel supply.

m) Provide an electrical design that meets the minimum requirements of 

NFPA 70, NFPA 77, and NFPA 780. Treat combustible liquids under 

pressure as a flammable liquid. 

n) Provide a canopy for protection from the elements of fixed facility 

assets and equipment per the “Canopies” paragraph of this chapter. 

o) Provide a canopy to preclude rain from the containment area when the 

requirements listed in the “Canopies” paragraph of this chapter are 

met.

p) Provide for egress and entrance of emergency response vehicles. The 

egress and entrance routes need to be large enough to allow both, 

trucks and emergency vehicles to leave and enter the facility

simultaneously. 

q) Provide means of inbound filtration for all products. The selection of 

filtration depends on anticipated impurities, the source of fuel, and the 

shipping methods. See “Special In-Bound Filtration” paragraph and 

Table 4-1 in this chapter of this UFC. 

4-3.2.2 Tank Truck and Tank Car Drop Tank Off-Loading System

The introduction of air into a fuel receiving system poses extreme hazards which can 

result in fire and/or explosion. Hazards are compounded when an air/fuel mixture is 

passed through receipt filter/separators where static electricity is generated and ignition 

can occur. Design off-loading facilities so air is not introduced into the system. For 

facilities with the capability to off-load several tank trucks at once or where newer tank 

trucks with multiple hoses are connected to multiple isolated compartments, consider 

providing an underground, gravity-type, receiving tank with deepwell turbine transfer 

pumps and level controls. For smaller systems of one or two tank trucks, consider 

providing a low profile, aboveground, receiving tank with a centrifugal transfer pump. 

For either case, provide level sensors to control the transfer rate. Provide a meter on 

the receipt line to the tank at points of custody transfer and when directed. For 

materials of construction for off-loading drop tanks, refer to Chapter 8. See Facility 

Plate 003. 
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4-3.2.3 Tank Truck and Tank Car Packaged Off-Loading System

For tank truck or tank car off-loading an off-loading drop tank may not be practical due 

to environmental concerns, site limitations, or cost considerations. In these instances, 

provide a 600 gpm (38 L/s) packaged off-loading system. Provide one packaged 

system, including vertical inline centrifugal pump, diaphragm control valves to control 

flow, meter, and multiple hose connections (one for each tank truck compartment), for 

each tank truck or tank car receiving station. Provide an air eliminator tank to remove 

air from the system, reducing the risk of an air/fuel mixture passing through receipt 

filter/separators and preventing the metering of air. Level sensors in the air eliminator 

tank control the pump discharge diaphragm control valves, modulating the flow rate 

based on the level in the air eliminator tank. Refer to NAVFAC Drawing No. 1404005

and Facility Plate 004. 

4-3.2.4 Tank Truck and Tank Car Direct Off-Loading System

Use when only an occasional tank truck requires off-loading and when directed by 

Service Headquarters. Refer to Facility Plate 005. 

4-3.2.5 Equipment Required

a) When tank trucks or tank cars are off-loaded with a drop tank offloading system, do not provide an off-loading pump. Provide at least 

two pumps in the drop tank to transfer fuel to the storage tank.

b) When tank trucks or tank cars are off-loaded with packaged off-loading 

systems, provide one system for each tank truck or tank car that is to 

be off-loaded simultaneously, at an average capacity of 600 gpm (38 

L/s) each. The number of systems shall be determined by Service 

Headquarters but shall be a minimum of two. The capacity of the 

systems may be reduced to 300 gpm (19 L/s) each only when directed 

by Service Headquarters. 

c) When tank trucks or tank cars are off-loaded with direct off-loading 

systems, provide centrifugal pumps configured to provide automatic air 

elimination as shown on Facility Plate 005. Provide at least two pumps 

to allow continued operation if one is out of service. The capacity of 

the pumps may be increased to 600 gpm (38 L/s) each only when 

directed by Service Headquarters. The centerline height of suction line 

from manifold to pump should not exceed 23.25 inches (591 mm) 

above truck unloading, parked position. Locate the pump as close as 

possible to the off-load point to prevent suction problems.

d) When tank trucks or tank cars are off-loaded with a drop tank offloading system, do not provide an off-loading pump. Provide at least 

two pumps in the drop tank to transfer fuel from the drop tank to the 

storage tank.
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e) Provide 4-inch (100 mm) diameter by 10-foot (3 m) long lightweight 

reinforced vacuum rated off-loading hoses and covered hose storage 

racks for each hose connection at each off-loading position. Ensure 

that all swivels are non-lubricated aluminum or stainless steel in-line 

repairable type.

f) Equip each tank truck off-loading position with an electronic, 

intrinsically safe, automatic, self-monitoring ground verification unit with 

a lockable bypass. If grounding is not verified and there is an offloading pump dedicated to that position, ensure the unit prevents the 

pump from starting. If the pump is not dedicated, ensure an alarm 

sounds if the off-loading valve is opened prior to grounding verification. 

Include a separate grounding reel to accommodate vehicles without 

grounding equipment. 

g) Provide emergency fuel shutoff (EFSO) pushbutton stations. For truck 

off-loading stations with multiple positions, an EFSO pushbutton 

station is required for each position and along routes of personnel 

ingress and egress between 100 and 200 feet from the off-loading 

position. Design in such a manner that activation of the emergency 

stop will shutoff all fueling in the off-loading area and/or it associated 

pumphouse or pump pad.

h) Provide fuel sampling connections at each position for each product 

line for collecting test samples.

i) Provide pressure gauges on both sides of each strainer or a differential 

type gauge across each strainer. Where a strainer is upstream of a 

pump, the pump suction gauge may function as the strainer 

downstream gauge.

j) Provide a compound (pressure/vacuum) gauge on the inlet side of the 

pumps and a pressure gauge on the outlet side of pumps.

k) If system is for JP-5 or other fuel that does not have a static dissipation 

additive which provides a conductivity level greater than 50 

picosiemens, and a 30-second retention time is not provided between 

filter/separator and receiving tank, provide a relaxation tank or design 

the piping layout to provide the required 30-second relaxation time 

downstream of filter/separator. 

l) Provide basket strainers upstream of pumps, meters and receipt 

filtration. 

m) Provide a combination flow control and non-surge check diaphragm 

control valve on all off-loading pumps except positive displacement 

types. If a bulk air eliminator with automatic air release head is 
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included, provide a means of closing the diaphragm control valve with 

a solenoid pilot.

n) Provide a positive displacement or turbine meter and meter proving 

connections. Provide meter with temperature compensation capability 

wherever custody transfer occurs. Provide a basket strainer on the 

upstream side of the meter.

o) On each off-loading connection or on the off-loading riser, install a 

visual fuel flow indicator (maximum pressure 275 psi (1900 kPa) at 100 

degrees F (38 degrees C), with Viton Seals with a maximum 

temperature rating of 350 degrees F (177 degrees C)). This will allow 

visual quality assurance and provide the operator with a backup 

system to shut off the pumps when off-loading is complete to prevent 

air build-up in the receipt lines.

p) Provide filter/separators and other filtration devices as described in 

Table 4-1 to filter fuel before it enters the storage tank.

q) Provide manual isolation valves to isolate equipment for service.

r) Provide thermal relief valves around isolation and check valves to 

relieve excessive pressures caused by thermal expansion of liquid 

trapped between shutoff points. See Facility Plates 023, 024, 025 and 

026. 

s) For JP-8 systems, provide a capability to defuel JP-8 refueler trucks 

back into operating storage as described in the paragraph titled 

“Defueling and Return-to-Bulk Systems” in this chapter.

t) Where tank trucks or tank cars are off-loaded into drop tanks provide a 

meter on the receipt line to the tank only when directed by Service 

Headquarters. 

4-3.3 Marine Off-Loading Facilities

See Chapter 5 of this UFC

4-3.4 Special In-Bound Filtration

Where fuel is transferred to the base fuel system operating tanks from tankers, barges, 

or directly from the supplier (off base) by a multi-product pipeline, pass the fuel through 

strainers, then pre-filtration, then fine filtration. In other cases, pass the fuel through 

strainers and fine filtration only. See Table 4-1 of this chapter for details. 

4-4 DISPENSING FACILITIES

4-4.1 Refueler Truck Fillstands

Mission and turn-around times will establish the number of fill positions, with two being 

the minimum. Service Headquarters can assist in determining the number. See Facility 
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Plates 006 and 007 for general design guidance and also DoD Standard Design AW 78-

24-29, Type IV/V. Provide a separate loading system for each grade or type of fuel to 

be handled.

4-4.1.1 General Criteria

a) Locate the refueler loading facility as close as practical or permissible 

to the location of the aircraft to be fueled but not less than 50 feet (15

m) from tanks, buildings, roads, overhead power lines, pad-mounted 

transformers, and property lines. 

b) For aircraft direct fueling systems, the fuel supply piping to the refueler

truck loading facility may be a spur or extension from that system and 

constructed of the same material as that system. In this case, the 

filter/separators are not required since they are provided as part of the 

aircraft direct fueling system. Where filtration is downstream of the 

pump house and the spur connects prior to the filtration equipment, a 

filtered lateral is required. 

c) Arrange fuel loading equipment on one or more concrete islands 

configured for refueling on one side only. Make the direction of traffic 

appropriate for the location of the loading connections on the refueler, 

located on the driver's side. When more than one island is required 

because of the volume or number of fuel grades to be handled, 

arrange them in a parallel fashion with approximately 15 feet (4.6 m) 

between adjacent sides. Arrange the islands and approaches to allow 

forward motion for all trucks at all times with ample room for turning. 

Allow for egress and entrance of emergency response vehicles.

d) Provide a containment area at each truck loading position, consisting 

of an impermeable retention and controlled drainage system leading to 

a concrete remote spill containment. Pave the containment area 

consisting of the islands, the spaces between islands and on each side 

of the outer islands, with concrete pitched a minimum of one percent 

toward catch basins or trench drains. Design the containment areas in 

accordance with UFC 1-200-01, federal, state, and local regulations. 

Do not use asphalt within a spill containment area. The maximum 

slope of any paving a within truck movement or parking area shall not 

exceed 2 percent excepting rollover curbs. If a rollover curb is 

provided, the sum of the vertical entrance and exit grades shall not 

exceed 8 percent, the horizontal length of the curb in the direction of 

truck movement shall not be less than 15 feet, and the rollover curb 

shall be aligned perpendicular with direction of truck movement. 

e) At tank car loading areas, pave the containment area with concrete (or 

otherwise provide containment) for an area extending from 5 feet (1.5 

m) outside of each outer rail and extending longitudinally 15 feet (4.6 
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m) each way from the center of each loading position. Slope the 

paved area to a spill containment system as described previously in 

item (d).

f) Provide a concrete remote spill containment system for each 

containment area. Design the remote spill containment system in 

accordance with UFC 1-200-01, federal, state, and local regulations. 

Provide the remote spill containment system with capacity greater than 

either the volume of the largest refueler to be loaded or the runoff from 

a rainfall of intensity equal to a 5-year expectancy for a 1-hour 

duration. Provide a lockable knife gate valve with indicator post 

located outside the enclosure in an area that will be safely accessible 

during a fire. The valve on the drain system shall be lockable and 

normally closed to allow for containment during fueling operations and 

which can be opened to drain the area when necessary. Tank trucks 

can be as large as 10,000 gallons (38 000 L) in capacity. If a canopy 

is installed, reduce the sizing for rainfall, accounting only for windblown rain. Consider combining the remote spill containment systems 

with other spill containment systems on-site, except with tank 

containment systems. However, take the level of contamination in 

each containment area into consideration. 

g) Construct the drain piping between the containment area and the 

concrete remote spill containment system, and between the remote 

spill containment system and lockable knife gate valve of petroleumresistant, fire-resistant, impermeable materials. Do not use clay, 

concrete, fiberglass, or plastic piping materials.

h) Load aircraft refueler trucks by bottom loading only. Design the 

system to deliver a nominal flowrate of 600 gpm (38 L/s) with a 

pressure refueling nozzle pressure of 35 psig (240 kPa). System 

design shall take into consideration pressure and flow settings to 

prevent damage to bottom loader. Contact Service Headquarters for 

further direction.

i) Provide a canopy for protection from the elements of fixed facility 

assets and equipment per the “Canopies” paragraph of this chapter.

j) Provide a canopy to preclude rain from the containment area when the 

requirements listed in the “Canopies” paragraph of this chapter are 

met.

k) Design all electrical systems and apparatus for use in Class I, Division 

1, Group D, hazardous areas in accordance with NFPA 70, regardless 

of the type of fuel dispensed.
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l) Provide for egress and entrance of emergency response vehicles. The 

egress and entrance routes need to be large enough to allow both, 

trucks and emergency vehicles, leaving and entering the facility.

m) For JP-8 systems, provide a capability to defuel JP-8 refueler trucks 

back into operating storage as described in the paragraph titled 

“Defueling and Return-to-Bulk Systems” in this chapter. 

4-4.1.2 Equipment Required

Provide separate piping, pumps, loading connections, and controls for each different 

type or grade of fuel. Provide an individual isolation valve for each fill connection. 

Include the following equipment in each refueler truck fillstand:

a) Self-closing emergency valve with 165 degrees F (74 degrees C)

fusible link (These valves are not required nor permitted on Air Force 

projects).

b) Provide manual isolation valves to isolate equipment for service.

c) Provide thermal relief valves around isolation and check valves to 

relieve excessive pressures caused by thermal expansion of liquid 

trapped between shutoff points. See Facility Plates 023, 024, 025 and 

026. 

d) Provide filter/separator, unless fillstand is supplied from an aircraft

direct fueling system via a non-ferrous branch connection downstream 

of the issue filter/separator. 

e) Positive displacement or turbine meter with rated capacity equal to the 

maximum flow of the loading station and the following accessories:

(1) If custody transfer point: a combination ticket printer and large 

numeral zero reset counter with self-closing weatherproof cover. 

Ticket printer not required on Army or Air Force projects.

(2) Pulse transmitter of the photoelectric, high resolution type 

required for projects which employ electronic data acquisition 

systems. 

(3) Temperature compensation if at a custody transfer point.

f) Provide relaxation tank or piping configuration with sufficient capacity 

to retain the maximum flow of the loading station for 30 seconds from 

the time the fuel leaves the last piece of filtration equipment to the fuel 

reaching the loading pressure refueling nozzle. Applies only to JP-5 or 

other fuels which do not have a static dissipation additive that provides 

a conductivity level greater than 50 picosiemens per meter.
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g) Mechanical loading arm. The preferred device is a non-lubricated,

swiveled, stainless steel, counterbalanced mechanical loading arm. As 

an option, with the approval of Service Headquarters, use a loading 

hose approximately 10 feet (3 m) long, 3 or 4-inch (75 or 100 mm) 

nominal diameter, and meeting requirements of EI Std 1529. A spiral 

protective device (slinky) may be installed around the hose. House the 

hose in a covered hose tray to protect from ultraviolet damage. Install 

with a non-lubricated stainless steel in-line repairable swivel.

h) SAE AS5877 pressure refueling nozzle of size and type compatible 

with truck-loading connections (coded for product use, if more than one 

type of fuel is issued at the fillstand). Connect the pressure fueling 

nozzle to the loading arm or hose with a dry-break quick disconnect.

i) Sample outlet with a 1/4-inch (8 mm) diameter sample point with 

probe, ball valve, and quick disconnect at each position for each 

product line.

j) Make provisions to start and stop the pumps with start and stop pump 

controls at each position. Include pump status indicator light on control 

box.

k) A hydraulically operated diaphragm control valve with the following 

functions (care must be taken to select equipment which is compatible 

with electronic or mechanical meter stacks):

(1) Adjustable rate of flow control if fillstand is on a branch line from 

an aircraft direct fueling system or other multiple pump 

arrangement which could result in issue exceeding 600 gpm (38 

L/s).

(2) Pressure regulating to maintain desired upstream or downstream 

pressures. 

(3) Adjustable time delay for opening and closing speed control.

(4) Control valve to close in the event of diaphragm failure.

(5) Thermal relief to relieve excessive pressures caused by thermal

expansion of liquid trapped between shutoff points.

(6) Position indicator.

(7) Solenoid Shutoff. Interlock the solenoid with the electronic highlevel shutoff, ground verification, and deadman control.

l) Provide each fill position with an electronic high-level shutoff, ground 

verification, and deadman control system. The system shall be 
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intrinsically safe and self-checking. Interlock the system with either the 

solenoid operated truck loading diaphragm control valve or the pump 

such that the valve cannot remain open or the pump cannot operate if 

the tank truck compartment is full, the tank truck is not grounded, or 

the deadman is released. Ensure the system is compatible with both 

electronic and fiber optic sensors with manual-keyed bypass. (May 

require a parallel effort beyond the project scope to ensure that all 

trucks using the facility have compatible connections. If facility has 

trucks that do not have fixed probes, use cane probes instead.) (This 

unit is optional on Army projects with only tactical refuelers. Contact 

the Service Headquarters for guidance.)

m) Provide emergency fuel shutoff (EFSO) pushbutton stations. For 

fillstands with multiple positions, an EFSO pushbutton station is 

required for each position and along routes of personnel ingress and 

egress between 100 and 200 feet from the fillstand. Design in such a 

manner that activation of the emergency stop will shutoff all fueling at 

that pump house or pump pad.

n) Low-intensity area lighting, in accordance with API RP 540, to permit 

full visibility of all equipment and controls during night operations.

o) Refer to Chapter 2 of this UFC for information on vapor collection and 

recovery or disposal systems.

p) On/off station for pumps, if pumps are dedicated to fillstand. Provide a 

light to indicate on/off status.

q) Grounding reel and grounding plate as detailed in Standard Design 

AW 78-24-29, Type III with multiple connections.

r) Provide basket strainer upstream of pumps, meters, and where a 

filter/separator is not provided at the load rack.

s) Pressure gauge.

t) Maintenance drains.

u) Vents.

v) Provide hydraulic shock surge suppressors (if required).

w) For JP-8 systems, to allow defueling of refueler trucks, provide a 

Return-To-Bulk (RTB) station by providing a MIL-STD MS 24484

aircraft refueling adapter a point upstream of receipt filtration. 

Acceptable locations include the return line at a truck fillstand, the 

return line at a hydrant hose truck check-out station, the return line at a 

pantograph flush station, the product recovery tank, or at a truck 
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off-load station. Provide one SPR connection per group of fillstands or 

truck off-load stations. If into a product recovery tank, do not bypass 

the level control valve.

x) Meter proving connections, unless local procedure provides an 

alternative.

4-4.2 Aircraft Direct Fueling Systems

Aircraft direct fueling systems are fuel systems that deliver fuel directly into an aircraft 

and require additional fueling hardware, such as a hydrant hose truck, pantograph, or 

hydrant hose cart. These may be Type III hydrant systems (DoD Standard Design AW 

78-24-28) for portable pantographs or hydrant servicing trucks/carts; or may be hard 

piped with fixed pantographs, which is usually the case for Type V in-shelter fueling

(DoD Standard Design AW 78-24-29) and Type IV hot fueling stations (DoD Standard 

Design AW 78-24-29). While individual components may vary slightly between the 

various aircraft fueling systems, the basic philosophy of a system configured in a loop 

with no dead ends, is followed by all the services. The loop is made up of the 

supply/return piping with a flushing/back-pressure control valve that maintains a 

constant pressure on the supply side piping and relieves excess fuel not taken on by the 

aircraft(s) into the return portion of the piping and back to the tank. The lead pump is 

turned on either automatically by a drop in the system pressure or manually by an on/off 

switch at each direct fueling station. A venturi in the supply piping senses flow rate in 

the loop and works in conjunction with a venturi in the return loop. Depending on the 

flow demand, the return venturi turns on/off additional pumps as required. If return flow 

is below a preset limit (indicating that fuel is being dispensed), a low flow is sensed and 

additional pump(s) are turned on, one at a time, until a steady flow condition is reached. 

Conversely, if the return flow is above a preset limit (indicating less fuel is being 

dispensed), the return venturi senses high flow conditions and turns the pump(s) off, 

one at a time, until the system is brought to rest. The continued circulation of the fuel 

not only provides a self-cleaning action but when properly adjusted, the system is able 

to more closely match the varying fuel filling rates of aircraft. This provides smooth 

operation and helps eliminate destructive surge pressure spikes. In order to ensure the 

highest quality of fuel, contact with bare carbon steel is limited to an absolute minimum 

prior to filtration and is not permitted downstream of the issue filter/separators, unless 

specifically authorized by Service Headquarters.

4-4.2.1 General Requirements

Install aircraft direct fueling systems only when specifically authorized. Service 

Headquarters or MAJCOMs assist in determining the number and type of stations 

required by the activity and with locating hydrant pits in aircraft parking ramps. 

Construct new facilities only for issuing aviation turbine fuels through pressurized 

refueling nozzles and closed circuit fueling nozzles. Locate fueling stations at the edge 

of the aircraft parking apron or taxiways or at apron parking spots for large frame 

aircraft. Size and configure these systems based on the types of aircraft to be refueled, 

aircraft fuel capacity, and the number and types of aircraft to be simultaneously 

refueled. A parking plan shall be approved before proceeding with the hydrant pit layout 

design. Some aircraft, such as fighters and some helicopters, may be refueled with 
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engines running. See Facility Plates 008, 009 and 010. For additional guidance on Air 

Force projects, refer to AFH 32-1084. 

4-4.2.2 Fixed-Wing Small-Frame Aircraft

Locate aircraft direct fueling stations for small-frame aircraft (carrier aircraft, patrol 

aircraft, fighter aircraft, and small transports) along the edge of designated access 

ramps, aprons, or fueling lanes with easy access by aircraft and as close to their normal 

taxi routes as practical while still meeting centerline clearance requirements. Provide 

facilities for fueling aircraft with engines or support equipment running. These systems 

are installed where the mission dictates a continuing need for rapid turnaround without 

shutting engines down and are located to permit quick return to the runway. Configure 

taxi patterns to and from fueling stations to keep jet blast away from people. Refer to 

DoD Standard Design AW 78-24-29 and Navy Definitive Design No. 1404000. Use the 

following design criteria:

a) Outside of the limits prescribed for clear areas by UFC 3-260-01 and 

UFC 3-260-02, locate the equipment aboveground on a concrete slab 

adjacent to the edge of an access ramp, apron, or fueling lane. Ensure 

that the width of the slab and location of the equipment, including the 

pantograph when retracted, with respect to the ramp, apron, or fueling 

lane, does not interfere with any part of the aircraft on its approach to 

or departure from the fueling station. Equip Army and Navy hot fueling 

stations with an emergency dry breakaway coupling. 

b) Limit the height of the equipment, including lighting, on the slab to no 

more than 30 inches (762 mm) above nominal grade. Contact Airfield 

Manager for additional clearances. 

c) Provide a nominal maximum flow rate for each direct fueling station of 

600 gpm (38 L/s). However, design the system to deliver 400 gpm (25 

L/s) with a nozzle pressure of 35 psig (240 kPa). Ensure adequate 

pump design for 600 gpm flowrate. (In general, systems designed to 

deliver 400 gpm at 35 psig have been shown to be fully capable of 

delivering 600 gpm with a nozzle pressure reading of 10 to 20 psig.) 

Actual fueling rates for small-frame aircraft range from 250 to 550 gpm 

(16 to 35 L/s). Since the actual flow rate will vary as the nozzle back 

pressure varies, it is necessary to limit the maximum nozzle pressure 

to 55 psig (380 kPa) at the skin of the aircraft to protect the aircraft. 

The issue venturi in a pantograph is a critical component of the aircraft 

direct fueling system and must be able to correctly simulate nozzle

pressure and compensate for all pressure losses up to and including 

the fueling nozzle. Use maximum rates and the number of required 

simultaneous refuelings for system sizing.

d) Provide at least two fueling stations, with the system sized for a 

minimum flow rate of 1,200 gpm (76 L/s). Where more than two 

fueling stations are required, increase the total system rate by 600 gpm 
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(38 L/s) for every three additional fueling stations. Service 

headquarters and Major Command approval are required for systems 

exceeding 2400 gpm. However, systems are not recommended to 

exceed 3,000 gpm (including spare pump).

e) DOD has two variations of the standard design for fixed-wing, small 

frame aircraft direct fueling stations – Type IV (DoD Standard Design 

AW 78-24-29) and Type V (DoD Standard Design AW 78-24-29). Both 

variations use pantographs for fueling the aircraft. The Type V is the 

same as the Type IV except that the refueling points are located in 

hardened aircraft shelters. The Type V variation is also known as inshelter refueling.

f) Both hose-end and hoseless pantographs can be used with either 

Type IV or Type V aircraft direct fueling systems. Contact the service 

headquarters for which type of pantograph to use. Use SAE AS5877

pressure refueling nozzles on pantographs. Equip pantographs on 

Navy/Marine Corps projects with 55 psi hose end pressure regulators 

located just before the refueling nozzle. Refer to DoD Standard 

Design AW 78-24-29, Type IV/V.

4-4.2.3 Large-Frame Aircraft

Locate aircraft direct fueling stations for large aircraft (transports, cargo planes, tankers, 

long-range patrol planes, and bombers) adjacent to their normal parking positions. Use 

the following design criteria:

a) Individually determine the number of fueling stations required for each 

activity. This depends on the number of large aircraft based at the 

activity or the number of aircraft that will need refueling as transients. 

To accommodate the fueling of a number of aircraft within a given time 

span without moving them, more fueling stations are normally required 

than would actually be used at one time.

b) Provide a flow rate criteria for each fueling station of 600 gpm (38 L/s) 

or 1,200 gpm (76 L/s) at 45 psig (310 kPa) nozzle pressure. The 

selection of 600 gpm (38 L/s) or 1,200 gpm (76 L/s) is based on 

aircraft. Contact MAJCOM for guidance. Size combined system 

requirements in multiples of 600 gpm (38 L/s), starting at a minimum 

flow rate of 1,200 gpm (76 L/s) up to a maximum flow rate of 2,400 

gpm (152 L/s).

c) Design the piping, hydraulics, materials, and pumps in accordance with 

other paragraphs in this chapter.

d) Large aircraft such as transports and cargo planes can be fueled from 

flush-mounted hydrant pits (preferred method for Air Force projects). 

Flush-mounted hydrant pits are required to conform to DoD Standard 

Design AW 78-24-28 for Type III hydrant systems. Pantographs can 
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be used where normal aircraft parking positions can be located 

adjacent to edge of the ramp (fixed long-reach pantographs have a 

maximum reach of 135 feet (41 m)).

e) Use self-propelled hydrant hose trucks, Type III hydrant hose carts, or 

detachable pantograph assemblies to provide the connection from the 

flush-mounted hydrant pits to the aircraft and the necessary controls. 

Provide a hydrant control valve that is hydraulically or pneumatically 

actuated and operated, depending on the type of mobile refueling 

equipment used. In order to ensure that the control valve is always in 

control and modulating and thus able to protect the aircraft, provide a 

differential pressure pilot with a set point of 15 psi (100 kPa). Provide 

Navy fueling stations with hose end controllers to limit pressure at the 

aircraft skin.

f) Equip pantographs in accordance with DoD Standard Designs. When 

incorporating the detachable pantograph into the design, follow 

USAFE/NATO specifications in which the swivels contain in-line 

repairable roller bearings. In addition, include the pantograph(s) as 

part of the construction project. Normally, the number of pantographs 

required equals the number of simultaneous refuelings to be 

performed.

g) The Air Force large-frame aircraft direct fueling system is referred to as 

a Type III pressurized fueling system. The Type III fueling system, or 

the constant pressure system, is the standard hydrant fueling system 

for large-frame aircraft. It is comprised of two operating storage tanks, 

a pump house, a hydrant loop, and hydrants at each parking position. 

The system is controlled by two redundant PLCs and is constantly 

pressurized when in operation. Fuel is pumped from the tanks, 

through filter separators and a supply venturi into the hydrant loop. It 

flows through the appropriate hydrant valve, through a hydrant 

servicing vehicle or mobile pantograph, into the aircraft if refueling is 

underway. A backpressure control valve keeps system pressure at a 

pre-set level and a return venturi measures flow back to the storage 

tank. Working in conjunction with the return venturi, pumps are turned 

on and off depending on refueling requirements. This system is sized 

in 600 gpm (38 L/s) increments up to 2,400 gpm (152 L/s). Issue 

pumps are sized to provide a minimum of 100 psi (690 kPa) at the 

outlet of the most distant hydrant adapter. Each hydrant pit control 

valve is equipped with a pressure control and surge shutdown pilot. 

These pilot controls are set at 45 psig (310 kPa) and 50 psig (345 

kPa), respectively. The hydrant control valves allow nominal flow rates 

up to 900 gpm (57 L/s) using a 4-inch valve and nominal flow rates up 

to 1200 gpm (76 L/s) using a 6-inch valve. Contact Service 

Headquarters for specific guidance and sizing of the hydrant control 
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valve. Refer to DoD Standard Design AW 78-24-28 for Type III 

hydrant systems. 

4-4.2.4 Helicopters

Refer to DoD Standard Design AW 78-24-29, Type IV, and use the following design 

criteria for designing direct fueling systems for helicopters: 

a) Design piping, pumps, controls, accessories, and auxiliary systems in 

accordance with other applicable paragraphs of this chapter. For each 

direct fueling station, provide a nominal maximum flow of 300 gpm (19 

L/s). Design system to be capable of delivering 275 gpm (17 L/s) at 35 

psig (240 kPa) nozzle pressure. Make the minimum size system 600 

gpm (38 L/s) with at least two fueling stations. For diversity usage, 

increase by 300 gpm (19 L/s) for every three additional fueling stations. 

At outlying fields and with Service Headquarters’ approval, a single 

fueling station may be used.

b) Provide aboveground direct fueling stations equipped identical to fixedwing small-frame aircraft fueling stations. Design the horizontal 

position and vertical projection of fueling equipment to avoid 

interference with the helicopters' blades when in the drooped attitude.

c) Coordinate the type of pressure refueling nozzle, SAE AS5877 or 

closed-circuit, with the end user.

4-4.2.5 Surface-Effect Hovercraft

Turbine-powered, surface-effect hovercraft can be fueled on the parking apron with 

aircraft direct fueling systems. Use a 200 gpm (13 L/s) maximum fueling rate at 30 psig 

(207 kPa) nozzle pressure. The fueling hardware components are similar to those 

required for aircraft direct fueling with JP-5. Orient fueling stations so that the blast 

generated from the turbine engine does not damage the direct fueling station 

components. Refer to DoD Standard Design AW 78-24-29, Type IV.

4-4.3 Marine Loading Facilities

See Chapter 5 of this UFC.

4-5 PIPING SYSTEMS

Refer to Chapter 9 of this UFC for information and guidelines regarding piping systems.

4-5.1 Product Segregation

Except as otherwise approved by Service Headquarters, prevent contamination of 

aviation turbine fuel by providing separate receiving, storage, and distribution systems 

for each product. Except as otherwise approved by Service Headquarters prevent 

misfueling (transferring a type of fuel other than that intended) by using different size 

piping, valves, adaptors, nozzles, etc. 
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4-6 EQUIPMENT DESCRIPTIONS

The appropriate guide specifications and/or standard design will provide specific 

information for equipment selection. Make provisions to drain equipment for 

maintenance. Provide hard piped drains when the equipment holds more than 5 gallons 

(19 L) of fuel or when a pipe which drains to the product recovery tank is within 12 feet 

(3.7 m) of the equipment.

4-6.1 Bulk Air Eliminators

Use flange-connected, steel bodied bulk air eliminator of the desired pressure and flow 

rating for the applicable service requirement. Include an automatic air release head and 

interlock the equipment with a float or solenoid-operated hydraulically operated 

diaphragm control valve. Provide discharge piping to the product recovery tank or other 

safe means of containment.

4-6.2 Meters

Provide meters with swivel mounted counter heads at truck fillstands to accommodate 

varying truck and operator positions.

4-6.2.1 Meters – Positive Displacement

Use flange-connected, cast steel bodied (except aluminum or stainless steel if after the 

issue filter/separator) positive displacement meters of the desired pressure and flow 

rating for the applicable service requirements. Ensure meter has case drain and 

register. Provide temperature compensation and adjustable calibration capabilities 

where there is custody transfer. Ensure meter accessories are compatible with either 

the mechanical or electronic support equipment selected. Provide an accuracy of plus 

or minus 0.5 percent when used for custody transfer. Consult the appropriate Service 

Headquarters for requirements for the meter to communicate to a remote location or 

equipment. Consider the use of a card-operated or key-operated data acquisition 

system. Cards or keys, as appropriate, are coded to identify the receiver of the fuel and 

to allow access to the fuel. The quantities taken are transmitted to a data-receiving 

device by electronic pulse transmitters mounted on each meter, and each transaction is 

automatically recorded.

4-6.2.2 Meters – Turbine

Use flange-connected, stainless steel-bodied turbine meters of the desired pressure 

and flow rating for the applicable service requirement. Provide a flow straightener 

before turbine meters or provide a straight length of pipe at a minimum of ten pipe 

diameters upstream and five pipe diameters downstream of all turbine meters, or as 

required by manufacturer. Ensure meter has case drain and register. Provide

temperature compensation and adjustable calibration capabilities where there is 

custody transfer. Ensure all supporting equipment for meter is compatible with the 

turbine meter selected. Provide an accuracy of plus or minus 0.5 percent when used for 

custody transfer. Consult the appropriate Service Headquarters for requirements for the 

meter to communicate to a remote location or equipment. Consider the use of a cardoperated or key-operated data acquisition system. Cards or keys, as appropriate, are 

coded to identify the receiver of the fuel and to allow access to the fuel. The quantities 
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taken are transmitted to a data-receiving device by electronic pulse transmitters 

mounted on each meter, and each transaction is automatically recorded.

4-6.3 Pressure or Pressure/Vacuum Gauges

Use liquid-filled gauges of range and dial size, as necessary, but not less than 0 to 160 

pounds per square inch (0 to 1100 kPa) pressure range and 4-inch (100 mm) diameter 

dial. Gauges are to be of all stainless steel construction, with black graduations on a 

white face. For locations where the temperature exceeds 100 degrees F (38 degrees 

C), consult Service Headquarters for direction on the possible use of gas-filled gauges. 

For locations where the temperature is less than -40 degrees F (-40 degrees C), use 

appropriate gauge liquid that will not freeze to prevent damaging the gauge.

a) Consider the location, year-round weather conditions, and service 

requirements for the type of liquid filling to be used.

b) Gauge liquids and service ranges:

Liquid Range

Glycerin 0 °F to 400 °F 

(-18 °C to 204 °C)

Silicone -40 °F to 600 °F 

(-40 °C to 316 °C)

c) Provide a lever handle gauge cock and pressure snubber in each 

pressure gauge connection.

d) Provide indicating and recording pressure gauges on suction and 

discharge lines for interterminal pipeline pumping stations and on the 

incoming line at the delivery terminal of each such pipeline, if required 

by Service Headquarters. 

e) Pressure gauges shall be installed so that they are testable without 

removing them from the piping.

4-6.4 Strainers

Require a strainer to protect centrifugal pumps, unless it precludes meeting the net 

positive suction head of the pump. Whether or not strainers are installed on the suction 

side of centrifugal pumps, require a spool piece so that temporary strainers can be 

installed during startup of the system. Strainers are required on the suction side of all 

positive displacement pumps, meters and receipt filtration. Strainers are not required 

upstream of issue filter/separators or diaphragm control valves. Also:

a) Use flanged basket strainers constructed of steel and fitted with 

removable baskets of fine Monel metal or stainless steel mesh with 

large mesh reinforcements. Provide quick opening, single screw type 

with drain connection in bottom.
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b) Provide a fine screen mesh as follows:

Mesh Size of Opening

Pump suctions (Centrifugal) 7 0.108 inch (2.74 mm)

Pump suctions (Positive 

Displacement) 40 0.016 inch (0.40 mm)

Receipt Filtration 40 0.016 inch (0.40 mm)

Meter inlets (unless downstream 

of a filter/separator) 40 0.016 inch (0.40 mm)

c) In all cases, ensure the effective screen area is not less than three 

times the cross sectional area of the pipe.

d) Provide pressure gauges on both sides of the strainer or a differential 

type gauge across the strainer.

4-6.5 Surge Suppressors

Every effort should be made to control hydraulic surge or shock to acceptable limits by 

the design of the piping system rather than by the use of surge suppressors. Where 

this is not possible or becomes extremely impractical, surge suppressors may be 

incorporated. Use the diaphragm or bladder type equipped with a top-mounted liquidfilled pressure gauge, wafer-style check valve at the bottom, drain above the check 

valve, and isolation valve. Provide a needle valve around the check valve to permit 

controlled bleed back of the surge suppresser without rebounding. Locate surge 

suppressors as close as possible to the point of shutoff that is expected to cause the 

shock. Surge suppressors can reduce shock pressure but will not eliminate it entirely. 

The preferred solution to hydraulic shock is conservative piping design, use of loops, 

and slow-closing valves. Surge suppressors are strictly a last resort solution and 

require the approval of Service Headquarters prior to designing into a system.

4-6.6 Filter/Separators

The common aviation turbine fuel contaminants are water, solids, surfactants, microorganisms, and miscellaneous contaminants. Solid contaminants are generally those 

which are insoluble in fuel, most common are iron rust, scale, sand, and dirt. However, 

metal particles, dust, lint from filter material and rags, gasket pieces, and even sludge

produced by bacterial action are included. The maximum amount and size of solids that 

an aircraft can tolerate vary by aircraft type and fuel system. Close Tolerance

mechanisms in turbine engines can be damaged by particles as small as 1/20th the 

diameter of a human hair. Filter/separators continually remove dirt and free water from 

aviation turbine fuels. Ensure that the design requires two separate filtrations prior to 

the fuel reaching the refueler truck fillstand, hydrant pit, or aircraft direct fueling station.

4-6.6.1 Design Requirements

All aviation turbine fuels pumped into an operating tank must pass through a 

filter/separator. Provide a filter/separator on the discharge line from the operating 

storage tank. Filter/separators are required for all aviation turbine fuel systems in 

facilities where the fuel is dispensed directly to aircraft or is loaded on refuelers that 
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eventually dispense the fuel to aircraft. As a minimum for such facilities, provide 

filter/separators as follows:

a) Design and construct filter/separators in accordance with EI 

Specification 1581(Edition 5). 

b) Elements for filter/separators shall meet the standard sizes described

in DESC-X-P-2. 

c) Provide horizontal filter/separators. Provide vertical filter/separators

only where space constraints prohibit horizontal units. Provide access 

to at least one side of every vertical unit via a separate (not attached to 

the filter/separator), stand alone, fixed platform.

d) Design and construct filter/separators in accordance with the American 

Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel 

Code Construct metal parts which will be in contact with the fuel, 

including the shell, head, and internal attachments of 3003 or 5083 

aluminum alloy. (The Air Force also allows interior epoxy-coated 

carbon steel.) Include the following accessories:

(1) Piston-type differential pressure gauge with 1 psi (5 kPa) 

graduations across the elements. Pressure gauge shall be 

testable without removal from the piping.

(2) Sight glass on the water sump.

(3) Hydraulically operated diaphragm control valve in the main 

discharge piping with rate of flow and water slug features. 

Include a manual check mechanism external to the 

filter/separator to check the float. (The water slug feature must 

not be included on pipeline, barge, or tanker receipt lines. In 

those cases, use a differential pressure alarm and a differential 

pressure-actuated bypass valve.)

(4) Only at barge-receiving locations or where large quantities of 

water are expected, automatic water drain valve connected to 

the bottom of the water sump. 

(5) Manual water drain valve from the bottom of the water sump.

(6) Safety relief valve in accordance with the American Society of 

Mechanical Engineers (ASME) Boiler and Pressure Vessel 

Code. 

(7) Thermal relief.

(8) Automatic air release with check valve.
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(9) Basket strainers upstream of all receipt filter/separators. 

(10) Connect automatic water drains, manual drains, thermal relief 

valves, and air releases to a permanently installed product 

recovery tank as described in Chapter 8 of this UFC.

(11) Fuel sample points upstream and downstream.

e) Do not provide sight gauges (sight flow indicators) on drain piping and 

pressure relief valves. Do not allow sight flow indicators to be installed 

on any filtration device.

f) Do not allow reverse flow thru filter/separators or any other filtration 

devices.

g) Provide a means to slow-fill the vessel. This is necessary to avoid 

static buildup during the filling of the filter/separator. DoD Standard 

Design AW 78-24-28 gives details for this design feature.

4-6.6.2 Arrangement

Arrange the system piping so that fuel from the discharge side of the fueling system 

transfer pumps can be recirculated back through the inlet filter/separators into the 

operating storage tank. Inlet filter/separators may serve more than one operating 

storage tank. In aircraft direct fueling systems on the downstream side of operating 

storage tanks, arrange the piping so that the fuel can be circulated from the operating 

storage tanks, through the filter/separators, to each aircraft fixed fueling station and 

back through the inlet filter/separators to the operating storage tanks. Provide 

dispensing filter/separators of the same number and capacity as the transfer pumps; 

that is, for three 600 gpm (38 L/s) pumps, provide three 600 gpm (38 L/s) 

filter/separators. 

4-6.7 Pumps

4-6.7.1 Design Requirements

Design pumps to deliver the full range of operating conditions anticipated at any facility 

with flow rates as presented in this chapter. Ensure pumps develop sufficient head to 

overcome the friction and static head losses in the system at the rated flow. Consider 

the specific gravity, temperature, viscosity, vapor pressure, corrosive, and solvent 

properties of the fuel. Provide at least two pumps for each aviation turbine fueling 

system. For any single grade of fuel, connect pumps in parallel. Select according to 

the type most suitable for the particular application. Do not use positive displacement or 

reciprocating pumps for product issue or pipeline transfer. Provide separate pumps for 

each type of aviation turbine fuel. Provide at least two transfer pumps, each capable of 

delivering the required system capacity.

4-6.7.2 Centrifugal Pumps

Use API Std 610 centrifugal pumps to pump from aboveground tanks with continuously 

flooded suctions.
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4-6.7.3 Vertical Turbine Pumps

Use API Std 610 vertical turbine pumps to pump from underground tanks. Do not use 

horizontal transfer pumps in a pit alongside the underground tank. Provide a foot valve 

on all vertical turbine pumps on Navy and USAFE Projects.

4-6.7.4 Rotary Pumps

Use sliding vane positive displacement pumps or self-priming centrifugal pumps for 

applications such as stripping pipelines or similar service where the pump may 

frequently lose its prime. For these pumps, provide a pressure relief valve located on 

the discharge side of the pumps. A variable speed motor can be used on positive 

displacement pumps to gradually bring the pump to normal operating speed. 

Note: On positive displacement pumps the pressure relief valve shall be considered 

safety relief valves, not operating valves (valves that modulate on a normal basis to 

maintain a set pressure). Use of the relief valve to modulate the pump discharge 

pressure voids the pump warranty. 

4-6.7.5 Drivers

Drive permanently installed pumps by an electric motor which is properly classified in 

accordance with NFPA 70. Size drivers shall be non-overloading at any point on the 

curve. Provide anti-reversing ratchets on all vertical turbine pump motors.

4-6.7.6 Materials of Construction

For aviation turbine fuels, require cast steel or nodular iron casings and stainless steel 

impellers and trim. Consider nonferrous materials in severe corrosive environments, 

consult Service Headquarters. 

4-6.7.7 Installation

Mount permanently installed pumps on substantial foundations of reinforced concrete, 

designed in accordance with Hydraulic Institute Standards. 

4-6.8 Valves

4-6.8.1 Materials of Construction – Aviation Turbine Fuel Service

Valve materials in contact with aviation turbine fuel shall either be stainless steel,

chrome plated carbon steel, or electroless nickel plated carbon steel. Do not allow zinc, 

zinc-coated, copper, or copper bearing materials in contact with the fuel. Do not allow 

internally epoxy-coated valves. 

Require manual valves in aviation turbine fuel systems to have stainless steel bodies 

and bonnets. Carbon steel bodied valves are permitted provided they are internally 

plated with nickel plating. Do not allow aluminum, cast iron, or bronze bodied valves. 

Use only API fire-safe valves.

4-6.8.2 Isolation Valve Types

a) Double Block and Bleed Isolation Valves: 
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(1) Use these for separation of product services, on tank shell 

connections, when piping goes above or below ground, between 

pier and tank storage, and other locations critical to pressuretesting of piping.

(2) Plug Valves (Double Block and Bleed): Use double-seated, 

tapered lift, lockable, plug type valves with a body bleed between 

the seats (double block and bleed). Valves shall be designed so 

that if the synthetic seating material is burned out in a fire, a 

metal-to-metal seat will remain to affect closure and comply with 

API Std 607. Lubricated plug valves are not allowed. Include 

integral body cavity thermal relief valve. 

(3) Ball Valves (Double Block and Bleed): Use double-seated, 

trunion mounted, lockable, ball type valves with a body bleed 

between the seats (double block and bleed). These will be very 

rarely used but are acceptable as an alternative to double block 

and bleed plug valves in applications where the valve is operated 

very infrequently. An example is isolation valve pits where they 

are only closed to perform pressure testing of piping. Valves 

shall be designed so that if the synthetic seating material is 

burned out in a fire, a metal-to-metal seat will remain to affect 

closure and comply with API Std 607. Include integral body 

cavity thermal relief valve. 

(4) Gate Valves (Double Block and Bleed): Use double-seated, 

lockable, gate type valves with a body bleed between the seats 

(double block and bleed). These will be very rarely used but are

acceptable as an alternative to double block and bleed plug 

valves and double block and bleed ball valves only when other 

double block and bleed valves will not physically fit. Valves shall 

be designed so that if the synthetic seating material is burned out 

in a fire, a metal-to-metal seat will remain to affect closure and 

comply with API Std 607. Single seated gate valves are not 

allowed. Include integral body cavity thermal relief valve. 

b) Quick Opening/Frequent Opening Isolation Valves: 

(1) Use these for less critical applications where double block and 

bleed shutoff is not required.

(2) Ball Valves: Ball type, lockable, valves designed so that if the 

synthetic seating material is burned out in a fire, a metal-to-metal 

seat will remain to affect closure and comply with API Std 607. 

Use Teflon or Viton synthetic seals or seating material. Use full 

port ball valves where line pigging is required or if within ten pipe 

diameters upstream and/or five pipe diameters downstream of a 
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flow or pressure control valve, or a flow-sensing device such as 

a venturi. Valves should comply with API Std 608. 

(3) Butterfly Valves: High-performance wafer trunion butterfly type 

valves designed so that if the synthetic seating material is 

burned out in a fire, a metal-to-metal seat will remain to affect 

closure and comply with API Std 607. Use Teflon or Viton 

synthetic seals or seating material. Use valves of highperformance type with eccentric disc shaft and clamping action 

for bubble-tight shutoff. Provide only at inlet to truck fillstand and 

on supply and return risers at aircraft direct fueling stations with 

fusible link set to release at 165 degrees F (74 degrees C). 

These valves are not required nor permitted on Air Force 

projects.

c) Use full port valves with exact same diameter of the pipe when line 

pigging is required.

4-6.8.3 Isolation Valve Operators

Provide manually operated valves not specified for remote, automatic, or emergency 

operation. Use geared operators for ball and double block and bleed valves larger than 

6 inches (150 mm). Double block and bleed gate, ball and double block and bleed 

valves specified for remote, automatic, or emergency service may have electric motor 

operators, if approved by Service Headquarters. Provide locking tabs on isolation 

valves to allow padlock to be used for lock-out during maintenance. Provide chain 

operators on valves which are located 72 inches (1800 mm) or higher above grade.

4-6.8.4 Isolation Valve Locations

Provide isolation valves in product piping systems to control flow and to permit isolation 

of equipment for maintenance or repair. Provide additional valves at required locations 

necessary to conduct a valid hydrostatic test. Require manually operated valves, 

except where motor operators are specifically authorized by applicable standard 

drawings or technical specifications. Use double block and bleed type isolation valves 

for separation of product services, on tank shell connections (ASTs over 12,000 gallons

only), when piping goes above or below ground, between pier and tank storage, and 

other locations critical to periodic pressure-testing of piping. Quick opening/frequent 

opening type isolation valves may be used for less critical applications where double 

block and bleed shutoff is not required. As a minimum requirement, provide isolation

valves at the following locations:

a) Provide double block and bleed valves where piping goes 

below/aboveground and requires periodic pressure testing.

b) At all subsurface and aboveground piping connections to storage 

tanks. 

c) On each branch line at the point of connection to the main product 

pipeline or header.
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d) On the product pipeline or header just before the line leaves a pumping 

station.

e) On the suction side and discharge side of each pumping unit, except 

the suction side of vertical centrifugal pumps installed in underground 

tanks. 

f) At all aircraft fuel dispensing points.

g) On the inlet and outlet connection of each line strainer, filter/separator, 

meter, diaphragm control valve, and other equipment that requires 

periodic servicing. One inlet valve and one outlet valve may be used 

to isolate more than one piece of adjacent equipment which are 

connected in series.

h) On the aboveground piping at each tank car or tank truck off-loading 

connection. This requirement does not apply to gravity off-loading 

lines unless isolation valves are specifically called for on applicable 

drawings.

i) On the aboveground piping at each refueler loading connection.

j) At critical points where pipes cross runways, roads, and taxiways.

4-6.8.5 Isolation Valve Pits

Provide fiberglass or concrete pits with a rolling or hinged cover designed in accordance 

with the DoD Standard Design AW 78-24-28 for all isolation valves installed in nontraffic areas on underground fuel systems. Design valve pits and valve operators so 

that the valves can be operated by personnel, without confined space entry.

4-6.9 Other Valves (Except Diaphragm Control Valves)

 

4-6.9.1 Check Valves

Use check valves to prevent backflow through pumps, branch lines, meters, or other 

locations where runback or reverse flow must be avoided. Check valves may be of the 

swing disk, globe, dual plate hinged disk, spring-loaded poppet, ball, or diaphragmactuated types. Use checks of soft-seated non-slamming type with renewable seats 

and disks. Ensure check valves conform to API Spec 6D. Use non-surge check 

diaphragm control valves with flow control feature on the discharge of all pumps. When 

using non-surge check diaphragm control valves on pump discharge, consider the use 

of a spring type wafer check before the diaphragm valve to prevent sudden flow 

reversals during shutdown from passing back thru the pump before the diaphragm 

control valve diaphragm chamber is filled and reacts by closing the valve. 

4-6.9.2 Thermal Relief 

Provide thermal relief valves around isolation and check valves to relieve excessive 

pressures caused by thermal expansion of liquid trapped between shutoff points. See 

Facility Plates 023, 024, 025 and 026. 
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4-6.10 Diaphragm Control Valves

Hydraulically operated, single-seated, globe type, diaphragm actuated valves are used 

extensively in fueling systems as control valves. These valves consist of a main valve 

and a pilot control system. The valve is operated by varying the amount of pressure 

above the diaphragm. Since the chamber above the diaphragm exposes a greater area 

of the diaphragm to chamber pressure than the area of the disc exposed to line 

pressure, an equal pressure in the chamber and pipeline results in a greater force being 

applied to the top of the disc. This forces the disc against the seat, thus closing the 

valve. By selecting the proper pilot control system, these valves can be used in 

numerous ways to control flow, pressure, and level within fueling systems.

4-6.10.1 Open/Close Operation

This is the most basic function of hydraulically operated diaphragm control valves. The 

operation is accomplished by applying pressure above the diaphragm to close the valve 

and relieve that pressure to allow line pressure to open the valve. The pilot trim used to 

perform this operation is a three-way valve which can be controlled by a solenoid, hand, 

pressure, pressure differential, or a float.

4-6.10.2 Throttling Operation

This is the other main method of controlling the hydraulically operated diaphragm 

control valve. In this case, the valve modulates to any degree of opening, in response 

to changes in the throttling control. The throttling control reacts to a pressure, or a 

pressure differential across the main valve, or pressure differential across an orifice 

plate to regulate the position of the disc in the main valve. For proper operation these 

valves should be installed with straight pipe on both sides of the valve. Ten pipe 

diameters on the upstream side and five diameters on the downstream side is sufficient; 

provide full port manual isolation valves if they are placed within these limits. 

4-6.10.3 Check Valve Function

This is a unique function of a control valve. In this case, the main valve outlet pressure 

is connected to the diaphragm cover. Therefore, if the downstream outlet pressure 

exceeds the inlet pressure, which normally holds the valve open, the valve will close 

and prevent backflow. Note: In order for the valve to close, it must backflow, 

sometimes for a substantial amount of time. Consider putting a regular check valve in 

series with this valve in cases where this is a concern.

4-6.10.4 Remote Operations

Hydraulically operated diaphragm control valves can be operated remotely. This is 

accomplished by installing tubing from the point of pressure sensing to the valve or by 

using remote-controlled solenoids within the trim.

4-6.10.5 Materials of Construction

Use stainless steel pilots and stainless steel tubing. Use bodies, bonnets, and covers 

made of stainless steel, internally plated (chrome) steel, or internally plated (nickel) 

nodular iron. Provide Viton or Buna-N diaphragm and disc ring. Enclose all electrical 

apparatus according to classification of the area in which they are installed. Provide a 

means to wire seal all adjustable pilots. Do not use aluminum valves. 
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4-6.10.6 Applications

For fueling systems, use hydraulically operated diaphragm control valves in the 

following applications (also refer to specific chapters for applications):

a) Water slug shutoff. 

b) Rate of flow control.

c) Pressure reduction.

d) Pressure relief.

e) Liquid level control.

f) Non-surge check control.

g) Deadman control. 

h) Electrical block control.

4-6.10.7 Combinations

A combination of these controls is also possible. A typical use of these controls is on a 

filter/separator for water slug shutoff and rate of flow control.

4-6.11 Fuel Hoses

Use sizes as required for design flow rates. For hose flanges and nipples, use carbon 

steel or brass, except at aviation turbine fuel issue points use brass, stainless steel, or 

aluminum where metal parts contact the fuel.

4-6.11.1 Loading Fuel Hoses

Provide pressurized loading hoses and connections complying with EI Std 1529. 

4-6.11.2 Off-Loading Fuel Hoses 

Provide lightweight, flexible, non-pressurized off-loading hoses constructed of nitrile 

rubber, rigid polyvinyl chloride (PVC) helix, synthetic braiding, smooth bore, and 

corrugated outer diameter. Provide non-pressurized hoses with a 65 psi (450 kPa) 

rating at 72 degrees F (22 degrees C) and 27 in Hg (90 kPa) vacuum rating.

4-7 CONTROLS

4-7.1 Design Requirements

Automatic controls at any facility may include temperature, pressure, fuel level and 

pump controls, automatic flow controls, alarm and limit switches, motor operated 

isolation valves, solenoid pilot actuated diaphragm control valves, and remote system 

condition indicators. Other forms of automatic controls are remote meter indication, 

electronic access control, data logging, and application of computer techniques. Base 

the selection of advanced automation and telemetry systems on a study of the particular 
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application with consideration of possible economic justification, operational, and 

security requirements.

4-7.2 Flow Controls

Where it is possible to achieve flow rates which exceed equipment ratings, provide an 

adjustable flow control diaphragm control valve on the outlet connection of each meter 

or filter/separator. Use a diaphragm control valve controlled by the pressure differential 

across an orifice plate in the valve or a venturi in the main line. Where necessary, 

provide remote-operated valves on storage tank inlet and outlet lines, suction and 

discharge of transfer pumps, and transfer lines at fuel piers and other locations.

4-7.3 Pump Controls

Operation of pump suction and discharge valves may be a part of the automatic 

sequence for the starting of a centrifugal pump and for shutting it down, remotely, 

locally, or by a protective shutdown device. Remote-operated valves on the discharge 

side of the pump can be either motor-operated or the solenoid pilot-type, hydraulically 

operated diaphragm control valves. Remote control valves on the suction side of the 

pump can be motor-operated valves only. Equip these valves with green and red (open 

and closed) indicating lights at their pushbutton control locations. Consider the use of 

PLCs on more complicated systems.

4-7.3.1 All Pumps

Provide the following controls:

a) A keyed hand/auto button at each pump and a keyed hand-off-auto 

switch at the motor starter for each remotely operated pump. Both 

devices will use the same key.

b) Indicator lights at the control station to give positive indications both 

when a pump is operating and when it is not energized. Use the 

"push-to-test" type.

c) A signal light or alarm to indicate pump failure when a pump is 

controlled automatically.

d) Reduced voltage starting if required by electric utility supplier or, in all 

cases, for pump motors greater than 50 hp (37 kW) and all vertical 

pumps.

e) Emergency fuel shut-off (EFSO) pushbutton stations, between 100 and 

200 feet from the pump in the expected ingress and egress direction, 

with maintained contacts. Provide additional EFSO pushbutton 

stations at the point of fuel delivery or receipt (tanks, piers, fillstands, 

etc.) using the same spacing and locations requirements.

4-7.3.2 Multi-Function Pumps

Multi-function pumps are typically used at small facilities and are designed and 

arranged to be able to perform different functions such as fuel loading, off-loading, or 
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transfer depending on how valves are aligned. Provide each function with the control 

system requirements for each function described elsewhere in this chapter. For each 

multi-task pump provide a manual selector switch to choose which set of control and set 

points the pump is to "look at" when performing a particular function. 

4-7.3.3 Transfer Pumps

Parallel transfer pumps supplying an issuing facility with varying demand flow rates 

must be sequenced automatically by flow-sensing sequence equipment. Lead pumps 

can be started by a pushbutton at an issuing facility, or automatically by a pressure 

switch actuated by a decrease in system pressure as might be caused by opening a 

valve at the issuing facility. This method requires the system to be pressurized at all 

times and is normally incorporated in the Type III hydrant system design. Incorporate 

the following control features:

a) Automatically controlled pumps with emergency stop buttons with lockkey reset at issuing stations and at the central supervisory control 

station.

b) Automatic shut-off of transfer pumps on loss of suction or no flow for 

more than 3 minutes. Upon automatic shut-off, a corresponding alarm 

at the central supervisory control station is activated.

4-7.3.4 Pipeline Pumps

For pumps over 150 horsepower (112 kW), provide protective shutdown devices with 

alarm at central supervisory control station in the event of the following:

a) High pump case temperature due to blocked discharge.

b) Excessive pump vibration.

c) Mechanical seal or packing gland failure.

d) High discharge pressure or loss of discharge pressure.

e) Excessive motor vibration.

f) High motor winding temperature.

g) Electrical interlocks which will prevent starting a pump if certain key 

valve settings are not correct and which will cause a pump shutdown if 

a key valve setting is changed.

h) Loss of pump suction pressure.

i) High-bearing temperature and/or loss of cooling water flow.
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4-8 CANOPIES

4-8.1 Canopies to Protect Fixed Assets

Unless otherwise directed by Service Headquarters, provide a canopy to protect fixed 

facility assets and equipment from the elements. Fixed facilities and equipment include 

but are not limited to: pump pads, filtration pads, meter pads, isolation valve pads, tank 

truck and tank-car off-loading and loading equipment pads, control panels, electrical 

panels, and motor control centers (MCCs). Ensure structural design is in accordance 

with UFC 1-200-01 and UFC 3-301-01. 

4-8.2 Canopies to Reduce Stormwater

Do not provide a canopy to preclude rain from reaching the containment area unless it 

is required by federal, state, or local regulations; or it is economically justified by 

reducing the size of the concrete remote spill containment or spill treatment system; or if 

directed by Service Headquarters. At a canopy over a tank truck or tank car loading 

and off-loading containment area, ensure that the underside of the canopy is high 

enough to provide operator head room when walking on top of the truck or car. Ensure 

structural design is in accordance with UFC 1-200-01 and UFC 3-301-01 . 

4-9 FUEL ADDITIVES

Provide storage facilities which store aviation turbine fuels with the equipment to inject 

fuel additives if directed by Service Headquarters. This will require proportional 

injectors with manual bypass, storage of additives, and recirculation of tanks through 

piping with injectors. If the additives have a corrosive characteristic, construct the 

system, including storage tanks, tank appurtenances, pumps if required, piping and 

associated fittings, valves, and injector assemblies of stainless steel components. 

Consult Service Headquarters for guidance as to which additives must be included.

4-9.1 Plus 100 Additive

Additives used to raise the thermal stability of jet fuel by a minimum of 100 degrees F

(38 degrees C) also act as surfactants that will disable the water removal properties of 

the filter/separators that do not meet the requirements of EI Specification 1581 (Edition 

5). Because fuel containing a thermal stability additive is issued only at designated air 

bases, the major command fuels engineer (for USAF air bases), Army Petroleum Office 

(for US Army airfields), or Naval Air Systems Command (AIR-4.4.5) (for USN/USMC 

stations) will provide direction as to those bases where its use is permitted and 

guidance concerning the location of additive injection equipment and additive storage 

facilities.

4-10 DEFUELING AND RETURN-TO-BULK (RTB) SYSTEMS

4-10.1 General Criteria

Acceptable locations for defueling and RTB Systems include the return line at a truck 

fillstand, the return line at a hydrant hose truck check-out station, the return line at a 

pantograph flush station, the product recovery tank, or at a truck off-load station.
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4-10.2 JP-5 Systems

4-10.2.1 Hydrant Systems

Because the degradation of flash point below the minimum JP-5 requirement can occur 

when other than JP-5 is defueled from aircraft directly into operating tanks, ensure that 

JP-5 direct fueling systems are not capable of defueling an aircraft back into hydrant 

systems and operating storage. Defuel aircraft into mobile tanker vehicles or into fixed 

dedicated defuel tanks.

4-10.2.2 Other

Do not provide a capability to defuel JP-5 refueler trucks back into storage unless 

directed by Service Headquarters.

JP-5 systems do not use fuel bowsers (mobile defuel tanks).

4-10.3 JP-8 Systems

4-10.3.1 Hydrant Systems – Hydrant Loop

Provide JP-8 hydrant systems with capability to defuel aircraft back into the hydrant 

systems and operating storage through the hydrant pit diaphragm control valves. 

4-10.3.2 Hydrant Systems – Other

To allow defueling of refueler trucks provide a Return-To-Bulk (RTB) station on the 

return line of a hydrant hose truck check-out station or a pantograph check-out station, 

or a pantograph flushing station. Provide one adapter per group.

4-10.3.3 Tank Truck and Tank Car Off-Loading

To allow defueling of refueler trucks, provide a Return-To-Bulk (RTB) station by 

providing a MIL-STD MS 24484 aircraft refueling adapter at a tank truck or tank car 

off-loading station. Provide one adapter per group of tank truck or tank car off-load 

stations. If defueling into a product recovery tank, do not bypass the level control valve.

4-10.3.4 Refueler Truck Fillstands 

To allow defueling of refueler trucks, provide a Return-To-Bulk (RTB) station by 

providing a MIL-STD MS 24484 aircraft refueling adapter at a point upstream of receipt 

filtration when the fillstand has a return line. Provide one adapter per group of refueler 

truck fillstands. If defueling into a product recovery tank, do not bypass the level control 

valve.

4-10.3.5 Fuel Bowsers (Mobile Defuel Tanks ) 

Provide a capability to empty JP-8 fuel bowsers mobile defuel tanks by providing a 

gravity drain connection on underground product recovery tanks, or by providing a 

pump at aboveground product recovery tanks. Do not bypass the product recovery tank

level control valve.
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4-11 PRODUCT RECOVERY SYSTEMS 

Provide a system with pumps, piping, valves, and tanks to collect and store usable 

aviation turbine fuel which would otherwise become waste from operational or 

maintenance activities. See Chapter 8 of this UFC.

4-11.1 Tank Trucks and Fuel Bowsers

Provide a capability to receive fuel from JP-8 tank trucks and JP-8 fuel bowsers into the 

product recovery tank, either at the product recovery tank location, the truck fillstands, 

or through a connection at the fuel receipt facility.

4-11.2 Return to Bulk

Provide a capability to return aviation turbine fuel from JP-5 and JP-8 product recovery 

tank back into operating storage by pumping the fuel into the receipt piping upstream of 

receipt filtration.
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Table 4-1. Aviation Turbine Fuel Receipt Filtration Table (1) (3)

ITEM

DESCRIPTION

PIPELINE MARINE TRUCK/RAIL SPP(IB) (1) SPP(IOT) (1) MPP(IB) (1) MPP(IOT) (1) B(IB) (1) B(IOT) (1) T(IB) (1) T(IOT) (1) OTRTT(IB) OTRTT(IOT) RC(IB) RC(IOT)

a. Provide strainers upstream of filter/separators.    2   1 1    

b. Provide pre-filtration consisting of pre-filter or coalescer 

vessels, or both. For a receipt rate of 1200 gpm or less, 

provide at least two equal sized vessels of each type in 

parallel, each sized to handle at least 100% of the 

normal off-loading flow rate. When the flowrate is over 

1200 gpm, provide two sets of each type of vessel 

installed in parallel, each set sized for 100% of the 

normal off-loading flow rate.

 2   1 1 

c. Consider pre-filtration consisting of pre-filter or 

coalescer vessels, or both. 

  2    

d. When receiving from a non-government controlled 

source: Provide fine filtration. For a receipt rate of 

1200 gpm or less, provide two equal sized 

filter/separators in parallel, each sized to handle at least 

100% of the normal off-loading flow rate. When the 

flowrate is over 1200 gpm, provide two sets of 

filter/separators installed in parallel, each set sized for 

100% of the normal off-loading flow rate.

  2   1 1 

e. When receiving from a non-government controlled 

source: Provide fine filtration consisting of a sufficient 

number of equally sized receipt filter/separators to 

handle 100% of the maximum expected flow, plus 

provide an equally sized spare filter/separator. 

 2    

(1) Tankers always, and barges and pipelines may, receive at greater than 2,800 gpm. In these cases, 

fuel is typically received without filtration into a breakout tank, usually for economic reasons. 

Contact Service Headquarters to determine what filtration is needed.

(2) MPP(IOT) included for information only. NEVER receive fuel from a Multi-Product Pipeline into an 

Operating Tank.

(3) This table will not typically apply to receipt into regional bulk storage centers such as Defense Fuel 

Support Points (DFSPs). These typically do not have filtration on receipt. Contact Service 

Headquarters for guidance.

SPP(IB) - Single Product Pipeline (Into Bulk)

SPP(IOT) - Single Product Pipeline (Into Operating Tank)

MPP(IB) - Multi-Product Pipeline (Into Bulk)

MPP(IOT) - Multi-Product Pipeline (Into Operating Tank) 

B(IB) - Barge (Into Bulk) 

B(IOT) - Barge (Into Operating Tank)

T(IB) - Tanker (Into Bulk)

T(IOT) - Tanker (Into Operating Tank)

OTRTT(IB) - Over the Road Tank Truck (Into Bulk)

OTRTT(IOT) - Over the Road Tank Truck (IOT)

RC(IB) - Rail Car (Into Bulk)

RC(IOT) - Rail Car (Into Operating Tank)
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Table 4-1 – (Continued) (3) ITEM

DESCRIPTION

PIPELINE MARINE TRUCK/RAIL SPP(IB) (1) SPP(IOT) (1) MPP(IB) (1) MPP(IOT) (1) B(IB) (1) B(IOT) (1) T(IB) (1) T(IOT) (1) OTRTT(IB) OTRTT(IOT) RC(IB) RC(IOT)

f.

When receiving from a government controlled source: 

Provide fine filtration consisting of a sufficient number of 

equally sized receipt filter/separators to handle 100% of 

the maximum expected flow.

 2 1 1    

g.

Provide each vessel with a feature to automatically 

switch the fuel stream to the other vessel when the 

differential pressure across the vessel reaches a preset 

limit. Require a warning signal to the operator that the 

switching operation has occurred. In cases of 

emergency, include the capability to bypass the inlet 

filter/separator bank.

   2   1 1 

h.

Disable filter/separator control valve water slug feature. 

Provide water conductance probe tied to an alarm in 

place of water slug float. Provide differential pressure 

alarm and differential pressure-actuated bypass valve.

   2   1 1 

i. Provide filter/separator sump with automatic water drain 

valve connected to the bottom of the water sump. (4) 2   1 1 

j.

Consider providing filter/separator sump with automatic 

water drain valve connected to the bottom of the water 

sump when large quantities of water are expected. (4)

   2 1 1 

(1) Tankers always, and barges and pipelines may, receive at greater than 2,800 gpm. In these cases, 

fuel is typically received into a breakout tank, usually for economic reasons. Contact Service 

Headquarters to determine what filtration is needed.

(2) MPP(IOT) included for information only. NEVER receive fuel from a Multi-Product Pipeline into an 

Operating Tank. 

(3) This table will not typically apply to receipt into regional bulk storage centers such as Defense Fuel 

Support Points (DFSPs). These typically have not filtration on receipt. Contact Service 

Headquarters for guidance.

(4) Consider also in any situation where large quantities of water are expected.

SPP(IB) - Single Product Pipeline (Into Bulk)

SPP(IOT) - Single Product Pipeline (Into Operating Tank)

MPP(IB) - Multi-Product Pipeline (Into Bulk)

MPP(IOT) - Multi-Product Pipeline (Into Operating Tank) 

B(IB) - Barge (Into Bulk) 

B(IOT) - Barge (Into Operating Tank)

OTRTT(IB) - Over the Road Tank Truck (Into Bulk)

OTRTT(IOT) - Over the Road Tank Truck (IOT)

RC(IB) - Rail Car (Into Bulk)

RC(IOT) - Rail Car (Into Operating Tank)

T(IB) - Tanker (Into Bulk)

T(IOT) - Tanker (Into Operating Tank)
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CHAPTER 5 - MARINE RECEIVING AND DISPENSING FACILITIES

5-1 FUNCTION

Design marine fuel receiving and dispensing facilities for the purpose of receiving fuel 

and/or loading fuel aboard ships, barges and boats for consumption or as cargo. In 

many cases, the marine receiving and dispensing facilities will be combined. Special 

requirements for aviation turbine Fuels are in Chapter 4 of this UFC.

5-2 FUEL PIERS AND WHARVES

Ensure that the structural design of fuel piers and wharves is in accordance with UFC 4-

152-01. When required and approved by the appropriate Service Headquarters, design 

fuel piers for dispensing and receiving fuel. Ensure that the size of the facility is 

compatible with the fuel requirements of the activity and the number of simultaneous 

loadings and off-loadings to be accommodated. For dispensing of fuel, consider the 

number, type, and size of vessels to be fueled or loaded to provide the required number 

and locations of fuel outlets. In most cases, use dedicated fuel piers and wharves for 

fuel receipt. Include in the design an energy absorbing fender system. Refer to 

NAVFAC Definitive Drawings 1403995 through 1403999.

5-3 BERTHING PIERS

In some cases, permanent fuel piping and equipment may be installed on berthing piers 

which were not primarily designed for handling fuel. Design such piers in accordance 

with UFC 4-152-01. These facilities are normally used only for dispensing fuel to 

surface combatants for consumption. Operational requirements usually dictate a clear 

berthing pier surface area. This imposes restrictions on the use of loading arms and 

above deck piping. For these areas, trench-contained piping may be considered. Prior 

to designing facilities on berthing piers for receiving and/or dispensing of bulk fuel for 

transport, review plans with appropriate port operations agency.

5-4 OFFSHORE MOORINGS

When operations of an activity do not warrant construction of fuel piers, provide offshore 

moorings for vessels to discharge or receive fuel through underwater pipelines 

connecting to the shore facility. Clearly mark the moorings so that the vessel, when 

moored, will be in the proper position to pick up and connect to the underwater 

connection. Coordinate offshore mooring systems with Naval Facilities Engineering 

Service Center, Ocean Construction Division (NFESC-OCD).

5-5 GENERAL REQUIREMENTS

Chapter 2, General Design Information, of this UFC contains important information on 

fueling facilities. Do not start the design of any fueling system without first becoming 

completely familiar with Chapter 2 of this UFC. In particular, refer to Chapter 2 for 

guidance on spill prevention, air quality control, and other environmental, safety and fire 

protection issues.

5-6 GENERAL LAYOUT

Provide pier loading and off-loading connections, with blind flange and with ball valve for 

throttling and isolation, at the pier edge for each product to be transported. The intent is 
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for a loading arm manifold with a separate manual isolation plug valve for each product 

connection. This will allow simultaneous loading and off-loading of different products, 

each through a dedicated arm. Provide a double block and bleed plug valve at the point 

which the line is being stripped. Use the following criteria:

a) Provide each branch line to the pier edge with a manual isolation valve 

located at the main line. Provide thermal relief valves around isolation

and check valves to relieve excessive pressures caused by thermal 

expansion of liquid trapped between shutoff points. See Facility Plate 

025. 

b) Do not provide a gauge outboard of the hose connection shutoff valve 

because hose movement will indicate the presence or absence of 

pressure in the hose.

c) If required, provide one or more loading arms at each station.

d) Provide a liquid-filled pressure gauge for each loading arm, located to 

be easily read from the operator position. This gauge is provided 

because the drybreak check valve at the end of the loading arm and 

the rigid piping will not intuitively indicate the presence or absence of 

pressure at the loading arm.

e) Provide for venting and draining of the branch lines and loading arm 

manifolds. Provide for manual venting of the branch lines, connect the 

vents to the oil waste line, similar to a sanitary vent system to avoid 

spillage. When pier drain lines cannot be sloped back to the pierhead 

stripping pumps, a design including separate oil waste drain lines, 

holding tank and dedicated stripping pump is a viable alternative.

f) Provide segregated handling of multiple products through the loading 

arms, while allowing easy selection of the products to be transported. 

Double block and bleed valves can be used for this application.

g) Provide a separate pipe and connection for ballast water or offspec 

fuel if the size of the facility and level of activity warrants it.

h) Provide each hose handling and loading arm area with fixed spill 

containment as defined in 33 CFR Part 154. 

i) Provide hydraulic shock surge suppressors (if required). 

5-7 PIPING SYSTEMS

Refer to Chapter 9 of this UFC for information regarding piping systems.

5-7.1 Piping Arrangement

In addition to complying with Chapter 9, use the following criteria:
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a) Where simultaneous deliveries of the same fuel may be made by more 

than one vessel, size fuel headers and related equipment for the total 

flow rates of all vessels discharging into the headers. Ensure that flow 

rates are in accordance with Chapter 2 of this UFC.

b) Place pier piping above the pier deck within a containment area for 

fueling piers and within a trench on berthing piers. Slope piping toward

shore to permit stripping. Use gratings as required to allow access 

across the piping.

c) Provide flexibility in the piping between the pier and the shore to allow 

for small movement of the pier relative to the shore. Use a suitable 

pipe bend or offset configuration, preferably in a horizontal plane, that 

will allow three-dimensional movement. If vertical bends are used, 

install vents and drains.

d) Provide flexibility in the piping along the pier to allow for pipe growth 

due to thermal expansion. Horizontal expansion loops are preferred. 

In cases where space is tight provide vertical expansion loops or 

bellows expansion joints where necessary. Where practical provide 

vertical expansion loops with vents and drains.

e) Include in the pier facilities, pipe manifolds for each fuel type arranged 

parallel to the face of the pier.

f) Pipe hangers are not allowed.

5-8 EQUIPMENT DESCRIPTIONS

5-8.1 Loading/Off-Loading Arms

Provide articulated marine loading arms for receiving and shipping fuel cargoes so that 

the connected vessel can move 15 feet (4.6 mm) forward, 15 feet (4.6 mm) aft, and 10 

feet (3 m) off the face of the pier and vertically as caused by loading or off-loading of the 

vessel and tidal changes, without damage to the arm. Provide a hydraulic power assist 

system for operating loading arms larger than 8-inch (200 mm) nominal size. Equip the 

end of the loader to be connected to the ship’s manifold with an insulating section, a 

standard ANSI forged steel flange, and a steel quick coupling device, manually or 

hydraulically operated. Refer to NAVFAC Drawing No. 1403997. Consider breakaway 

couplings for locations with strong current.

5-8.2 Fuel Hoses

Loading/off-loading arms are the preferred method to be used. Provide a facility for 

storing and protecting the hose as near as practical to the pier if hose is provided in lieu 

of loading/off-loading arm.

5-8.3 Submarine Fuel Hoses

Provide submarine fuel hose where offshore moorings are used. Use heavy duty, 

smooth bore, oil and gasoline, marine cargo, discharge hose rated for a working 
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pressure of not less than 225 psig (1550 kPa) and built-in nipples with Class 300 

flanges with stainless steel bolts and Monel nuts. Hoses should be U. S. Coast Guard 

certified.

5-8.4 Meters

Provide a turbine or positive displacement meter for each dispensing outlet that might 

be used simultaneously. With the approval of the appropriate Service Headquarters, 

use portable meters where fueling operations are intermittent. Also consider the use of 

alternative technologies such as ultrasonic meters. Require temperature compensation 

feature at each meter used for custody transfer.

5-8.4.1 Meters – Positive Displacement

Require flange-connected, cast steel bodied positive displacement meters of the 

desired pressure and flow rating for the applicable service requirements. Ensure meter 

has case drain and register. Provide temperature compensation and adjustable 

calibration capabilities when there is custody transfer. Ensure meter accessories are 

compatible with either the mechanical or electronic support equipment selected. 

Provide an accuracy of plus or minus 0.5 percent when used for custody transfer. 

Consult the appropriate Service Headquarters for requirements for the meter to 

communicate to a remote location or equipment. Consider the use of a card-operated 

or key-operated data acquisition system. Cards or keys, as appropriate, are coded to 

identify the receiver of the fuel and to allow access to the fuel. The quantities taken are 

transmitted to a data-receiving device by electronic pulse transmitters mounted on each 

meter, and each transaction is automatically recorded.

5-8.4.2 Meters – Turbine

Use flange-connected, steel bodied turbine meters of the desired pressure and flow 

rating for the applicable service requirement. Provide a flow straightener before turbine 

meters or provide a straight length of pipe at a minimum of ten pipe diameters upstream 

and five pipe diameters downstream of all turbine meters, or as required by 

manufacturer. Ensure meter has case drain and register. Provide temperature

compensation and adjustable calibration capabilities when there is custody transfer. 

Ensure all supporting equipment for meter is compatible with the turbine meter selected. 

Provide an accuracy of plus or minus 0.5 percent when used for custody transfer. 

Consult the appropriate Service Headquarters for requirements for the meter to 

communicate to a remote location or equipment. Consider the use of a card-operated 

or key-operated data acquisition system. Cards or keys, as appropriate, are coded to 

identify the receiver of the fuel and to allow access to the fuel. The quantities taken are 

transmitted to a data-receiving device by electronic pulse transmitters mounted on each 

meter, and each transaction is automatically recorded.

5-8.5 Strainers

Require a basket strainer to protect centrifugal pumps, unless it precludes meeting the 

net positive suction head of the pump. Whether or not strainers are installed on the 

suction side of centrifugal pumps, install a spool piece so that temporary strainers can 

be installed during startup of the system. Strainers are required on the suction side of 
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all pumps, meters, and receipt filtration. Strainers are not required upstream of issue 

filter/separators or diaphragm control valves. Also:

a) Use flanged basket strainers constructed of steel and fitted with 

removable baskets of fine Monel metal or stainless steel mesh with 

large mesh reinforcements.

b) Unless otherwise specified, provide a fine screen mesh as follows:

Mesh Size of Opening

Pump suctions (Centrifugal) 7 0.108 inch (2.74 mm)

Pump suctions (Positive 

Displacement) 40 0.016 inch (0.40 mm)

Receipt Filtration 40 0.016 inch (0.40 mm)

Meter inlets (unless downstream 

of a filter/separator) 40 0.016 inch (0.40 mm)

c) In all cases, ensure the effective screen area is not less than three 

times the cross sectional area of the pipe.

d) Strainers upstream of pump shall be quick opening, single screw type.

e) Provide pressure gauges on both sides of the strainer and a differential 

type gauge across the strainer.

5-8.6 Surge Suppressors

Every effort should be made to control hydraulic surge or shock to acceptable limits by 

the design of the piping system rather than by the use of surge suppressors. Where 

this is not possible or becomes extremely impractical, surge suppressor(s) may be 

incorporated. Use the diaphragm or bladder type equipped with a top-mounted liquidfilled pressure gauge, wafer-style check valve at the bottom, drain above the check 

valve, and isolation valve. Provide a needle valve around the check valve to permit 

controlled bleed back of the surge suppresser without rebounding. Locate surge 

suppressors as close as possible to the point of shutoff that is expected to cause the 

shock. Surge suppressors can reduce shock pressure but will not eliminate it entirely. 

The preferred solution to hydraulic shock is conservative piping design, use of loops, 

and slow-closing valves. Surge suppressors are strictly a last resort solution and 

require the approval of Service Headquarters prior to designing into a system.

5-8.7 Valves

5-8.7.1 Materials of Construction

Require valves to have carbon steel bodies and bonnets. Do not allow valves with 

aluminum, cast iron, or bronze materials. Use only API fire-safe valves.
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5-8.7.2 Isolation Valve Types

a) Double Block and Bleed Isolation Valves: 

(1) Use these for separation of product services, on tank shell 

connections, when piping goes above or below ground, between 

pier and tank storage, and other locations critical to pressuretesting of piping.

(2) Plug Valves (Double Block and Bleed): Use double-seated, 

tapered lift, lockable, plug type valves with a body bleed between 

the seats (double block and bleed) in critical applications such as 

separation of product services, when piping goes above or below 

ground, between pier and tank storage, and other locations 

critical to pressure-testing of piping. Valves shall be designed so 

that if the synthetic seating material is burned out in a fire, a 

metal-to-metal seat will remain to affect closure and comply with 

API Std 607. Lubricated plug valves are not allowed. Include 

integral body cavity thermal relief valve. 

(3) Ball Valves (Double Block and Bleed): Use double-seated, 

trunion mounted, lockable, ball type valves with a body bleed 

between the seats (double block and bleed). These will be very 

rarely used but are acceptable as an alternative to double block 

and bleed plug valves in applications where the valve is operated 

very infrequently. An example is isolation valves in the middle of 

piers that are only closed to perform pressure testing of piping. 

Valves shall be designed so that if the synthetic seating material 

is burned out in a fire, a metal-to-metal seat will remain to affect 

closure and comply with API Std 607. Include integral body 

cavity thermal relief valve. 

(4) Gate Valves (Double Block and Bleed). Use double-seated, 

lockable, gate type valves with a body bleed between the seats 

(double block and bleed). These will be very rarely used but are 

acceptable as an alternative to double block and bleed plug 

valves and double block and bleed ball valves only when other 

double block and bleed valves will not physically fit. Valves shall 

be designed so that if the synthetic seating material is burned out 

in a fire, a metal-to-metal seat will remain to affect closure and 

comply with API Std 607. Single seated gate valves are not 

allowed. Include integral body cavity thermal relief valve. 

b) Quick Opening/Frequent Opening Isolation Valves 

(1) Use these for less critical applications where double block and 

bleed shutoff is not required.
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(2) Ball Valves: Ball type valves may be used as valves for quick or 

frequent opening applications when a double block and bleed 

valve is not required. Ball valves shall be designed so that if the 

synthetic seating material is burned out in a fire, a metal-to-metal 

seat will remain to affect closure and comply with API Std 607. 

Use Teflon or Viton synthetic seals or seating material. Use full 

port ball valves with exact same diameter of the pipe within ten 

pipe diameters upstream and/or five pipe diameters downstream 

of a flow or pressure control valve, or a flow-sensing device such 

as a venturi. Valves should comply with API Std 608. 

c) Butterfly Valves: Butterfly valves are not allowed.

d) Use full port valves with exact same diameter of the pipe when line 

pigging is required.

5-8.7.3 Isolation Valve Operators

Provide manually operated valves not specified for remote, automatic, or emergency 

operation. Use geared operators for ball and double block and bleed plug valves larger 

than 6 inches (150 mm). Double block and bleed gate, ball and double block and bleed 

valves specified for remote, automatic, or emergency service may have electric motor 

operators, if approved by Service Headquarters. Provide locking tabs on isolation 

valves to allow padlock to be used for lock-out during maintenance. Provide chain 

operators on valves which are located 72 inches (1800 mm) or higher above grade.

5-8.7.4 Isolation Valve Locations

a) Provide an isolation valve on each line at the shore end. For piping 

used only for receiving fuel, also provide a check valve at the shore 

end. Use double block and bleed type, which may be motor-operated 

with remote control. To minimize surge potential, use a slow-closing 

speed, if possible.

b) Provide double block and bleed isolation valves on the aboveground 

piping at each barge or tanker off-loading and loading connection.

c) Provide double block and bleed isolation valves near the shoreline of a 

submerged pipeline to offshore moorings.

d) Provide double block and bleed isolation valves on the inlet and outlet 

connection of each line strainer, filter/separator, meter, diaphragm 

control valve, and other equipment that requires periodic servicing. 

One inlet valve and one outlet valve may be used to isolate more than 

one piece of adjacent equipment which are connected in series.

e) Provide thermal relief valves around all isolation and check valves to 

relieve excessive pressures caused by thermal expansion of liquid 
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trapped between shutoff points. See Facility Plates 023, 024, 025 and 

026. 

5-8.7.5 Isolation Valve Pits

Provide fiberglass or concrete pits with a rolling or hinged cover designed in accordance 

with the DoD Standard Design AW 78-24-28 for all isolation valves installed in nontraffic areas on underground fuel systems. Design valve pits and valve operators so 

that the valves can be operated by personnel, without confined space entry.

5-8.8 Other Valves

5-8.8.1 Check Valves

Use check valves to prevent backflow through pumps, branch lines, meters, or other 

locations where runback or reverse flow must be avoided. Check valves may be of the 

swing disk, globe, dual plate hinged disk, spring-loaded poppet, ball, or diaphragmactuated types. Use checks of soft-seated non-slamming type with renewable seats 

and disks. Ensure check valves conform to API Spec 6D. Use non-surge check 

diaphragm control valves with flow control feature on the discharge of all pumps. When 

using non-surge check diaphragm control valves on pump discharge, consider the use 

of a spring type wafer check before the diaphragm control valve to prevent sudden flow 

reversals during shutdown from passing back thru the pump before the diaphragm

control valve diaphragm chamber is filled and reacts by closing the valve. 

5-8.8.2 Thermal Relief 

Provide thermal relief valves around isolation and check valves to relieve excessive 

pressures caused by thermal expansion of liquid trapped between shutoff points. See 

Facility Plates 023, 024, 025 and 026. 

5-8.9 Pressure or Pressure/Vacuum Gauges

Use glycerin-filled or silicone-filled pressure gauges of range and dial size, as 

necessary, but not less than 0 to 160 psig (0 to 1100 kPa) pressure range and 4-inch 

(100 mm) diameter dial. Also:

a) Use pressure gauges upstream and downstream of strainers and 

filters/separators. A differential pressure gauge may be used in lieu of 

gauges on each side.

b) Install compound (pressure/vacuum) gauges on the suction side of 

each pump at fuel storage tanks.

c) Provide a lever handle gauge cock and pressure snubber in each 

pressure gauge connection.

d) Provide a pressure gauge on each side of the pipeline shutoff valve at 

the shore end of each pier-mounted pipeline. Provide the indicating 

pointer with a high-pressure-reading tell-tale indicator suitable for 

reporting the highest pressure experienced since last reset. Provide 

for non-contact resetting of the tell-tale by means of a small magnet.
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e) Provide a pressure gauge on each branch line at each fueling station 

on each pier-mounted pipeline. Ensure that the pressure gauge is 

legible from the fuel hose connection array and from the pantograph 

loading arm location (if provided).

f) Provide a pressure gauge on each marine loading arm assembly (if 

provided). Ensure that the gauge is visible by the operator.

g) Pressure gauges shall be installed so that they are testable without 

removing them from the piping.

5-8.10 Stripper Pumps

Provide positive displacement stripper pumps for emptying loading arms, hoses, and 

manifolds. Provide a stripper pump to reclaim each clean product from each main 

product line, or connect the product lines to the oil waste drain line. Conduct an 

economic analysis of the two alternatives to determine the appropriate choice. Larger, 

longer, or more frequently drained lines will favor the stripper pump choice. Use a 

stripper pump on multi-product lines, but do not exceed acceptable limits of cross 

contamination. Provide a dedicated stripper pump to each separate product line, such 

as aviation turbine fuels.

5-8.11 Excess Flow Sensors

In piping used for both loading and off-loading, provide a sensor that will alarm both the 

control room and at the pier to detect excess flow that might occur in the event of a line 

break. 

5-8.12 Solid Cyclonic Separators

In facilities which receive product by tankers or barge, consider the use of solid 

separators in the receiving lines as part of pre-filtration to remove gross impurities from 

the incoming product. In systems equipped with filter/separators in the receiving lines, 

locate strainers or cyclonic separators upstream of the filter/separator. Ensure that 

there is no slug valve feature on the filter/separator. Consider the use of automatic 

water drains. Do not allow reverse flow thru cyclonic separators.

5-8.13 Grounding Systems

Provide grounding systems for barges in accordance with UFC 3-460-03, Figure 9.2.

5-8.14 Special Considerations for AviationTurbine Fuels

For inbound filtration of aviation turbine fuels, refer to Chapter 4 of this UFC.

5-9 PRODUCT RECOVERY SYSTEMS

Provide a product recovery system to collect and store usable aviation turbine fuel that 

would otherwise become waste from operational or maintenance activities. Consider a 

product recovery system for other products. See Chapter 8 of this UFC for product 

recovery systems.
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5-10 WEATHER SHEDS

Provide adequate shelter for personnel, as well as for spill containment booms, 

absorbent material, and other weather-sensitive equipment.

5-11 CANOPIES

Provide a canopy, unless otherwise directed by Service Headquarters, for all 

aboveground equipment including pumps, meters, strainers, filters, control panels, 

electrical panels, and motor control centers (MCCs). Ensure structural design is in 

accordance with UFC 1-200-01 and UFC 3-301-01 . 

5-12 SPECIAL CALCULATIONS

Calculate pipeline filling/venting times and draining/stripping times. The larger and the 

longer the pipeline, the greater the volume of fuel required to fill the line and, therefore, 

the greater the volume of air required to be vented. Undersized vent lines will delay 

filling the lines and delay changeover of products in multiproduct lines. Size the vent 

lines to allow filling of the line at not more than four times the design transit time of the 

line. Connect vent line to the drain line to avoid spills to the environment. Check vent 

line air velocity, which must not exceed the allowable air velocity to avoid electrostatic 

buildup, in accordance with API RP 2003. Vent rate must be not less than the lowest 

allowable pumping rate from ship or shore. Vent rate must be less than the design 

transit velocity to minimize hydraulic shock.

5-13 SAFETY SHOWERS AND EYEWASH FOUNTAINS

Provide manual shutoff valves on the potable water branch to the safety shower and 

eyewash fountain. Provide a means to seal shutoff valve in the open position. This will 

ensure operation in an emergency, yet allow for servicing a single shower without 

shutting off potable water to the whole pier. Design for freeze protection in climates 

subject to freezing. Install safety showers and eyewash fountains in accordance with 

ISEA Z358.1.

5-14 TRAFFIC BOLLARDS

Provide traffic bollards to protect fueling piping and equipment on piers and wharves. 

Utilize concrete-filled steel pipe of minimum 4-inch (100 mm) diameter and 4-foot (1.2 

m) height, embedded in concrete or welded to a steel plate mounted on the structure.

5-15 SPECIAL DRAINAGE FOR FUELING PIERS

a) Provide an intercept system to collect oil spills. Place pipes on piers in 

a curb containment area with a drain system independent of the deck 

drainage. Provide containment also for loading arms and risers. 

Provide locking valves in normally closed positions on all containment 

areas along with sump pumps or other means of removing the spilled 

fuel to a collection point or tank.

b) In cases where the stormwater collected in the intercept system is 

contaminated, the water/fuel mixture should be treated as an oil spill as 

described previously.
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5-16 BALLAST TREATMENT AND SLUDGE REMOVAL

5-16.1 Ballast Receiving and Treatment Facilities

5-16.1.1 Design Requirements

It is the policy of the United States that there should be no discharge of oil or hazardous 

substances into or upon the navigable waters of the United States, adjoining shorelines, 

or into or upon the waters of the contiguous zone. Petroleum fuel facilities, which 

transfer fuel by barge or tanker or which fuel large ships, require ballast water collection 

and treatment facilities to receive and treat oily ballast from cargo or fuel tanks. Also:

a) Blend the fuel oil which has been reclaimed from the ballast water

during the collection and treatment process with boiler fuel oil for use in 

shoreside boilers. Perform a quality assurance check on the reclaimed 

fuel oil to ensure that it meets the minimum requirements for shoreside 

boiler fuel. Dispose of sludge accumulated during the collection and 

treatment of ballast water in accordance with applicable hazardous 

waste management disposal procedures.

b) Select and design the appropriate treatment system based on an 

evaluation of the types of oil/water mixtures that may be encountered 

at the particular facility. If possible, base the evaluation on samples of 

typical ballast water receipts and tank washings including the following:

(1) Whether they are simple mixtures, simple gravity suspensions, or 

chemically stable emulsions. 

(2) The specific gravity and viscosity of the oil in the mixture.

(3) Whether other substances, such as chemicals or bacteria, in the 

mixtures must be removed.

(4) The general condition of the ship’s tanks expected to be 

discharged (e.g., new, clean, coated, well maintained, or dirty 

and normally full of sludge, scale, and rust).

(5) Whether ballast water is clean sea water or polluted harbor 

water.

(6) Whether the treatment system proposed (“ship’s waste off-load 

barge” or fixed shore-based facilities) meets the standards of 

effluent water quality established by local environmental 

regulations.

c) If it is determined that both simple mixtures and emulsions are present, 

consider the possibility of using two segregated separate systems, one 

for gravity separation and the other for breaking emulsions. Avoid 

mixing the two types of suspensions when possible. For bilge water 
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and other contaminated oily wastes which require additional treatment, 

refer to UFC 4-832-01N, Industrial and Oily Wastewater Control or for 

Army and Air Force projects MIL-HDBK-1005/17, Nondomestic 

Wastewater Control and Treatment Design.

d) For typical schematic arrangement of ballast water treatment and 

disposal systems, refer to UFGS 44 42 53. 

5-16.1.2 Receiving and Settling Tanks

The minimal ballast water receiving facility usually requires two storage tanks, usually of 

equal capacity, to be used alternately as receiving and settling tanks. If these tanks are 

sized to allow 4 to 5 days undisturbed settlement, separation of simple suspensions of 

light oils in water can be achieved. Use welded steel vertical aboveground storage 

tanks designed and constructed in accordance with Chapter 8 of this UFC. In addition 

to complying with Chapter 8 of this UFC for construction appurtenances, provide the 

following fittings and appurtenances:

a) An automatic float gauge suitable for use with transmitting device for 

remote readout.

b) One cable-operated swing-line assembly on the oil outlet pipe.

c) One shell fill nozzle. 

d) Valved sample connections in the shell, having nonfreezing-type 

valves in cold climates, every 2 feet (0.6 m) vertically, easily accessible 

from the ladder or stairway.

e) When chemical feed is provided, a chemical feed inlet valve, to be 

nonfreezing type in cold climates.

f) When air blowing is provided, a perforated pipe air sparger for mixing. 

Make the perforations in the sides of the pipe to avoid plugging by 

settling solids. Use nonfreezing-type air inlet valve(s) in cold climates.

g) Sight glass or look box on oil outlet line.

h) Sight glass or look box on water outlet line.

i) Oil sump tank with high-level alarm.

j) Water and oil pumps as required to move fluids from receiving tanks or 

from oil sump tanks. For transfer of oily water, use low-speed-type 

pumps to minimize emulsification.

k) If heaters are required to reduce oil viscosity and promote separation, 

use either tank wall heaters or internal pipes. Keep internal pipes at 

least 2 feet (0.6 m) above the tank floor.
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l) Insulation for tanks that will be regularly heated.

m) Provide automatic temperature controls and thermometers for all 

heated tanks.

5-16.1.3 Oil/Water Separators

Separate water/fuel mixtures from storage or settling tanks with an API oil/water 

separator. Recycle the fuel portion and pass the water portion to another treatment 

process. Do not discharge water drawn from tanks to surface water without additional 

treatment and permits. Chapter 2 of this UFC contains design information for an API 

oil/water separator. 

5-17 SLUDGE REMOVAL SYSTEMS

5-17.1 Design Requirements

Install sludge removal systems where the accumulation of sludge in substantial 

quantities is likely to occur on a regular basis. Sources of such sludge are a ballast 

water treatment system, a contaminated fuel recovery system, or frequent cleaning of 

shore or ships’ tanks. If routine cleaning of clean product storage tanks occurs on an 

irregular basis, sludge removal systems are not required.

5-17.2 Sludge Disposal

a) Where possible, provide pumps, tanks, and piping to return sludge

containing recoverable oil to the contaminated oil recovery system. If 

this is not possible, consider transferring the sludge to a refinery or 

waste oil treatment facility. For additional details, refer to UFC 3-240-

02N or for Army projects, UFC 3-240-09FA. 

b) Provide a tank or tanks with transfer pump(s) for pumpable sludges

that are unreclaimable. Include piping for receiving sludge and for 

mixing other low viscosity waste oils for thinning as required. Ensure 

that tanks are dike-enclosed and have cone bottoms.

c) Provide tank heating where climate conditions prove necessary.

d) Coordinate sludge disposal method and design with facility 

environmental office.

e) Enclose the sludge disposal facility with a security fence to prevent 

unauthorized entry. Do not use this facility for disposal of sand, gravel, 

rust scale, or other solid nonpumpable matter found on tank bottoms. 

For further discussion of disposal methods, refer to NAVFAC MO-230. 

5-17.3 Piping Materials

Refer to Chapter 9 of this UFC for information regarding piping materials.
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CHAPTER 6 - INTERTERMINAL AND INSTALLATION PIPELINES

6-1 INTRODUCTION

This chapter provides guidance for the design of pipelines. Military pipelines are 

typically either interterminal pipelines which are cross country and connect government 

installations, or installation pipelines which connect POL facilities within an installation. 

The primary differences are that interterminal pipelines cross public and private 

properties, streets, highways, railroads, and utility rights-of-way, whereas installation 

pipelines do not. Interterminal pipelines may be dedicated lines connecting two or more 

facilities or privately owned common carrier lines serving several commercial or military 

shippers. In some cases, the shipping facility may consist of a relatively short spur 

which delivers the fuel to the suction side of a pumping station which is part of the main 

line of a larger pipeline system. Pipeline receiving and dispensing facilities are normally 

part of a bulk fuel storage facility, which is discussed in Chapter 3 of this UFC. Special 

requirements for aviation turbine Fuels are in Chapter 4 of this UFC.

6-2 GENERAL REQUIREMENTS

Chapter 2, General Design Information, contains important information on fueling 

facilities. Do not start the design of any fueling system without first becoming 

completely familiar with Chapter 2 of this UFC. 

6-3 DESIGN REQUIREMENTS

6-3.1 Fuel Segregation

Clean products, such as diesel fuel and distillate-type burner fuels, may be shipped in 

the same system without segregation. Batches are usually pumped product to product, 

but they may be separated by fresh or suitably treated water. Separate piping systems 

are required for residual fuels. For DoD projects, provide a dedicated pipeline for 

aviation turbine fuels.

6-3.2 Applicable Regulations

Interterminal and installation pipelines shall be designed as described below. Where 

federal, state, or local regulations are more restrictive than the requirements indicated, 

the more restrictive requirements shall apply.

6-3.2.1 Installation Pipelines

All installation pipelines shall be designed in accordance with ANSI/ASME B31.3. 

6-3.2.2 Interterminal Pipelines

The U.S. Department of Transportation regulates the design, construction and operation 

of interterminal pipelines for liquid petroleum. Intrastate interterminal pipelines shall be 

designed in accordance with ANSI/ASME B31.4. Interstate interterminal pipelines, shall 

be designed in accordance with the requirements of 49 CFR Part 195.

6-3.3 Sampling

Provide a means for taking samples of the products shipped.
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6-3.4 Pigging

Pipelines shall be smart piggable including long radius elbows and barred fittings unless 

otherwise directed by Service Headquarters. 

6-3.5 Surge Suppression

Provide surge suppressors for hydraulic shock when required. 

6-4 PIPING SYSTEMS

Refer to Chapter 9 of this UFC for information regarding piping systems.

6-5 EQUIPMENT

Equip all pipelines with meters and basket strainers, and provide the capability to install 

a proving meter.

6-5.1 Meters

6-5.1.1 Meters – Positive Displacement

Use flange-connected, cast steel bodied positive displacement meters of the desired 

pressure and flow rating to meet applicable service requirements. Ensure that meter 

has case drain and register. Provide temperature compensation and adjustable 

calibration capabilities where there is custody transfer. Ensure meter accessories are 

compatible with either the mechanical or electronic support equipment selected. 

Consult the appropriate Service Headquarters for requirements for the meter to 

communicate to a remote location or equipment.

6-5.1.2 Meters – Turbine

Use flange-connected steel bodied turbine meters of the desired pressure and flow 

rating to meet applicable service requirements. Provide a flow straightener before 

turbine meters or provide a straight length of pipe at a minimum of ten pipe diameters 

upstream and five pipe diameters downstream of all turbine meters, or as required by 

manufacturer. Ensure meter has case drain and register. Provide temperature

compensation and adjustable calibration capabilities where there is custody transfer. 

Ensure all supporting equipment for meter is compatible with the turbine meter selected. 

Consult the appropriate Service Headquarters for requirements for the meter to 

communicate to a remote location or equipment. Consider the use of a card-operated 

or key-operated data acquisition system. Cards or keys, as appropriate, are coded to 

identify the receiver of the fuel and to allow access to the fuel. The quantities taken are 

transmitted to a data-receiving device by electronic pulse transmitters mounted on each 

meter, and each transaction is automatically recorded.

6-5.2 Manual Valves

6-5.2.1 Materials of Construction

Require valves to have carbon steel bodies and bonnets. Do not allow valves with 

aluminum, cast iron, or bronze materials. Use only API fire-safe valves.
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6-5.2.2 Isolation Valve Types

a) Double Block and Bleed Isolation Valves: 

(1) Use these for separation of product services, on tank shell 

connections, when piping goes above or below ground, between 

pier and tank storage, and other locations critical to pressuretesting of piping.

(2) Plug Valves (Double Block and Bleed): Use lockable, doubleseated, tapered lift, plug type valves with an automatic body 

bleed between the seats (double block and bleed) in critical 

applications such as separation of product services, on each line 

at the shore end, when piping goes above or below ground, 

between pier and tank storage, and other locations critical to 

pressure-testing of piping. Valves shall be designed so that if 

the synthetic seating material is burned out in a fire, a metal-tometal seat will remain to affect closure and comply with API Std 

607. Lubricated plug valves are not allowed. Include integral 

body cavity thermal relief valve. 

(3) Ball Valves (Double Block and Bleed): Use double-seated, 

trunion mounted, lockable, ball type valves with a body bleed 

between the seats (double block and bleed). These will be very 

rarely used but are acceptable as an alternative to double block 

and bleed plug valves in applications where the valve is operated 

very infrequently. An example is isolation valves in the middle of 

piers that are only closed to perform pressure testing of piping. 

Valves shall be designed so that if the synthetic seating material 

is burned out in a fire, a metal-to-metal seat will remain to affect 

closure and comply with API Std 607. Include integral body 

cavity thermal relief valve. 

(4) Gate Valves: Use double-seated, lockable, gate type valves with 

a body bleed between the seats (double block and bleed). 

These will be very rarely used but are acceptable as an 

alternative to double block and bleed plug valves and double 

block and bleed ball valves only when other double block and 

bleed valves will not physically fit. Valves shall be designed so 

that if the synthetic seating material is burned out in a fire, a 

metal-to-metal seat will remain to affect closure and comply with 

API Std 607. Single seated gate valves are not allowed. Include 

integral body cavity thermal relief valve. 

b) Quick Opening/Frequent Opening Isolation Valves 
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(1) Use these for less critical applications where double block and 

bleed shutoff is not required.

(2) Ball Valves: Ball type valves may be used as valves for quick or 

frequent opening applications when a double block and bleed 

valve is not required. Ball valves shall be designed so that if the 

synthetic seating material is burned out in a fire, a metal-to-metal 

seat will remain to affect closure and comply with API Std 607. 

Use Teflon or Viton synthetic seals or seating material. Use full 

port ball valves with exact same diameter of the pipe within ten 

pipe diameters upstream and/or five pipe diameters downstream 

of a flow or pressure control valve, or a flow-sensing device such 

as a venturi. Valves should comply with API Std 608. 

c) Butterfly Valves: Butterfly valves are not allowed.

d) Use full port valves with exact same diameter of the pipe when line 

pigging is required.

6-5.2.3 Isolation Valve Operators

Provide manually operated valves not specified for remote, automatic, or emergency 

operation. Use geared operators for ball and double block and bleed valves larger than 

6 inches (150 mm). Double block and bleed gate, ball, and double block and bleed 

valves specified for remote, automatic, or emergency service may have electric motor 

operators with suitable torque limiting controls if approved by Service Headquarters. 

For remote valves, consider using solar battery packs to reduce cost of routing power 

for the motor operators. Provide locking tabs on isolation valves to allow padlocks to be 

used to lock out valves during maintenance. Provide chain operators on valves which 

are located 72 inches (1800 mm) or higher above grade.

6-5.2.4 Isolation Valve Locations

Provide valves in product piping systems to control flow and to permit isolation of 

equipment for maintenance or repair. Provide additional valves at required locations 

necessary to conduct a valid hydrostatic test. Provide manually operated valves, except 

where motor operators are specifically authorized by applicable standard drawings or 

technical specifications. Use double block and bleed type isolation valves for 

separation of product services, on tank shell connections (ASTs over 12,000 gallons

only), when piping goes above or below ground, between pier and tank storage, and 

other locations critical to periodic pressure-testing of piping. Quick opening/frequent 

opening type isolation valves may be used for less critical applications where double 

block and bleed shutoff is not required. Before adding isolation valves, evaluate piping 

system and make modifications to prevent pressure buildup caused by thermal 

expansion. Review paragraph on relief valves in Chapter 9 of this UFC. As a minimum 

requirement, provide isolation valves at the following locations:

a) Provide a double block and bleed isolation valve on each branch line at 

the point of connection to the main product pipeline or header.
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b) Provide a double block and bleed isolation valve on the product 

pipeline or header just before the line leaves a pumping station.

c) Provide a double block and bleed isolation valve at the inlet and outlet 

connection of each line strainer, filter/separator, meter, diaphragm 

control valve, thermal relief valve, and other equipment that requires 

periodic servicing. One inlet and one outlet double block and bleed 

isolation valve may be used to isolate more than one piece of adjacent 

equipment which are connected in series.

d) Provide a double block and bleed isolation valve on the upstream and 

downstream side of each line blind at connections to cross country 

pipelines.

e) Provide a double block and bleed isolation valve on each main 

distribution pipeline immediately downstream of the branch connection 

to each existing or future operating storage facility served by the 

pipeline.

f) Provide a double block and bleed isolation valve at intermediate points 

of approximately 10 miles (16 km) in cross country distribution 

pipelines to facilitate isolation of a section of the line for maintenance 

and repair.

g) Provide a double block and bleed isolation valve on each side of water 

crossing exceeding 100 feet (30 m) in width, and near the shoreline of 

a submerged sea pipeline.

h) Provide a double block and bleed isolation valve at critical points 

where pipes cross under runways, taxiways, and roadways.

i) For low-point drains and high-point vents.

6-5.2.5 Isolation Valve Pits

Provide fiberglass or concrete pits with a rolling or hinged cover designed in accordance 

with the DoD Standard Design AW 78-24-28 for all isolation valves installed in nontraffic areas on underground fuel systems. Design valve pits and valve operators so 

that the valves can be operated by personnel, without confined space entry.

6-5.3 Other Valves (Except Diaphragm Control Valves)

6-5.3.1 Check Valves

Use check valves to prevent backflow through pumps, branch lines, meters, or other 

locations where runback or reverse flow must be avoided. Check valves may be of the 

swing disk, globe, dual plate hinged disk, spring-loaded poppet, ball, or diaphragmactuated types. Use checks of soft-seated non-slamming type with renewable seats 

and disks. Ensure check valves conform to API Spec 6D. Use diaphragm non-surge 

check valves with flow control feature on the discharge of all pumps. When using non-
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surge check diaphragm control valves on pump discharge, consider the use of a spring 

type wafer check before the diaphragm valve to prevent sudden flow reversals during 

shutdown from passing back thru the pump before the diaphragm control valve 

diaphragm chamber is filled and reacts by closing the valve. 

6-5.3.2 Thermal Relief 

Provide thermal relief valves around shutoff and check valves to relieve excessive 

pressures caused by thermal expansion of liquid trapped between shutoff points. See 

Facility Plates 023, 024, 025 and 026. 

6-5.4 Diaphragm Control Valves

Hydraulically operated, single-seated, globe type, diaphragm actuated control valves 

are used extensively in fueling systems as control valves. These valves consist of a 

main valve and a pilot control system. The valve is operated by varying the amount of 

pressure above the diaphragm. Since the chamber above the diaphragm exposes a 

greater area of the diaphragm to chamber pressure than the area of the disc exposed to 

line pressure, an equal pressure in the chamber and pipeline results in a greater force 

being applied to the top of the disc. This forces the disc against the seat, thus closing 

the valve. By selecting the proper pilot control system, these valves can be used in 

numerous ways to control flow, pressure, and level within fueling systems. 

Use extreme care when including these valves on pipelines as they can significantly 

contribute to surge potential, if closing time is too short. When properly adjusted, they 

can reduce surges.

6-5.4.1 Open/Close Operation

This is the most basic operation of hydraulically operated diaphragm control valves. 

The operation is accomplished by applying pressure above the diaphragm to close the 

valve and relieve that pressure to allow line pressure to open the valve. The pilot trim 

used to perform this operation is a three-way valve which can be controlled by a 

solenoid, hand, pressure, pressure differential, or a float.

6-5.4.2 Throttling Operation

This is the other main method of controlling the hydraulically operated diaphragm 

control valve. In this case, the valve modulates to any degree of opening, in response 

to changes in the throttling control. The throttling control reacts to a pressure, or a

pressure differential across the main valve, or pressure differential across an orifice 

plate to regulate the position of the disc in the main valve; provide full port manual 

isolation valves if they are placed within these limits. 

6-5.4.3 Check Valve Function

This is a unique function of a control valve. In this case, the main valve outlet pressure 

is connected to the diaphragm cover. Therefore, if the downstream outlet pressure 

exceeds the inlet pressure, which normally holds the valve open, the valve will close 

and prevent backflow.
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6-5.4.4 Remote Operations

Hydraulically operated diaphragm control valves can be operated remotely. This is 

accomplished by installing tubing from the point of pressure sensing to the valve or by 

using remote-controlled solenoids within the trim.

6-5.4.5 Materials of Construction

Use stainless steel pilots and stainless steel tubing. Use bodies, bonnets, and covers 

made of stainless steel, internally plated (chrome) steel, or internally plated (nickel) 

nodular iron. Provide Viton or Buna-N diaphragm and disc ring. Enclose all electrical 

apparatus according to classification of the area in which they are installed. Provide a 

means to wire seal all adjustable pilots. Do not use aluminum valves.

6-5.4.6 Applications

For pipeline systems, use hydraulically operated diaphragm control valves in the 

following applications:

a) Rate of flow control.

b) Pressure reduction.

c) Pressure relief.

d) Excess flow shutdown.

6-5.4.7 Combinations

A combination of these controls is also possible. 

6-5.5 Strainers

Require a strainer to protect centrifugal pumps, unless it precludes meeting the net 

positive suction head of the pump. Whether or not strainers are installed on the suction 

side of centrifugal pumps, install a spool piece so that temporary strainers can be 

installed during startup of the system. Strainers are required on the suction side of all 

pumps, meters, and receipt filtration. Strainers are not required upstream of issue 

filter/separators or diaphragm control valves. Also:

a) Use flanged strainers constructed of steel and fitted with removable 

baskets of fine Monel metal or stainless steel mesh with large mesh 

reinforcements.

b) Unless otherwise specified, provide a fine screen mesh as follows:

 Mesh Size of Opening

Pump suctions (Centrifugal) 7 0.108 inch (2.74 mm)

Pump suctions (Positive 

Displacement) 40 0.016 inch (0.40 mm)

Receipt Filtration 40 0.016 inch (0.40 mm)

Meter inlets (unless downstream 

of a filter/separator) 40 0.016 inch (0.40 mm)
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c) In all cases, ensure the effective screen area is not less than three 

times the cross sectional area of the pipe.

d) Strainers upstream of pump shall be quick opening, single screw type

with drain connection at bottom. 

e) Provide pressure gauges on both sides of the strainer and a differential 

type gauge across the strainer.

6-5.6 Surge Suppressors

Every effort should be made to control hydraulic surge or shock to acceptable limits by 

the design of the piping system rather than by the use of surge suppressors. Where 

this is not possible or becomes extremely impractical, surge suppressor(s) may be 

incorporated. Use the diaphragm or bladder type equipped with a top-mounted liquidfilled pressure gauge, wafer-style check valve at the bottom, drain above the check 

valve, and isolation valve. Provide a needle valve around the check valve to permit 

controlled bleed back of the surge suppresser without rebounding. Locate surge 

suppressors as close as possible to the point of shutoff that is expected to cause the 

shock. Surge suppressors can reduce shock pressure but will not eliminate it entirely. 

The preferred solution to hydraulic shock is conservative piping design, use of loops, 

and slow-closing valves. Surge suppressors are strictly a last resort solution and 

require the approval of Service Headquarters prior to designing into a system.

6-5.7 Pigging Equipment

Equip all pipelines with outlets to allow the connection of pig launchers and receivers. 

Design the outlets so that they can accommodate internal nondestructive inspection 

trains. Provide sufficient curvature of bends in the pipeline to permit free passage for 

such equipment. Provide tees with, factory installed internal guide bars, at all branch 

connections. 

6-5.8 Pumps

Primary pumping facilities are discussed in Chapter 3 of this UFC. If multiple pump 

stations are required to keep pipeline pressure within safe limits, provide them at 

appropriate locations. Chapter 3 also provides guidance for those pumping facilities.

6-5.9 Sampling Connections

Provide connections for sampling fuels on each section of a fuel transfer piping system. 

Install sampling and testing connections at receiving points, tank outlets, inlet and outlet 

sides of filter/separators, fuel dispensing points, and between isolation valves so that 

remaining fuel in each portion of a fuel transfer pipeline can be sampled. Where 

possible, install sampling connections in vertical runs. Provide a 1/4-inch (8 mm) 

diameter sample point with a probe, ball valve, and quick disconnect with dust cap.

6-5.10 Special Consideration for AviationTurbine Fuels

For inbound filtration of aviation turbine fuels, refer to Chapter 4 of this UFC.
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6-6 PRODUCT RECOVERY SYSTEMS

Provide a product recovery system to collect and store usable aviation turbine fuel that 

would otherwise become waste from operational or maintenance activities. Consider a 

product recovery system for other products. See Chapter 8 of this UFC for product 

recovery systems.

6-7 CANOPIES

6-7.1 Canopies to Protect Fixed Assets

Unless otherwise directed by Service Headquarters, provide a canopy to protect fixed

facility assets and equipment from the elements. Fixed facilities and equipment include 

but are not limited to: pump pads, filtration pads, meter pads, isolation valve pads, tank 

truck and tank-car off-loading and loading equipment pads, control panels, electrical 

panels, and motor control centers (MCCs). Ensure structural design is in accordance 

with UFC 1-200-01 and UFC 3-301-01. 

6-7.2 Canopies to Reduce Stormwater

Do not provide a canopy to preclude rain from reaching the containment area unless it 

is required by federal, state, or local regulations; or it is economically justified by 

reducing the size of the concrete remote spill containment or spill treatment system; or if 

directed by Service Headquarters. At a canopy over a tank truck or tank car loading 

and off-loading containment area, ensure that the underside of the canopy is high 

enough to provide operator head room when walking on top of the truck or car. Ensure 

structural design is in accordance with UFC 1-200-01 and UFC 3-301-01. 

6-8 SPECIAL CALCULATIONS

Calculate pipeline filling/venting times and draining/stripping times. The larger and the 

longer the pipeline, the greater the volume of fuel required to fill the line and, therefore, 

the greater the volume of air required to be vented. Undersized vent lines will delay 

filling the lines and delay changeover of products in multiproduct lines. Size vent lines 

to allow filling of the line at not more than four times the design transit time of the line. 

Where applicable, connect vent lines to system drain lines to avoid spills to the 

environment. Check vent line air velocity, which must not exceed the allowable air 

velocity to avoid electrostatic buildup, in accordance with API RP 2003. Vent rate must 

be not less than the lowest allowable pumping rate from ship or shore. Vent rate must 

be less than the design transit velocity to minimize hydraulic shock.
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CHAPTER 7 - GROUND PRODUCTS FUELING FACILITIES

7-1 INTRODUCTION

This chapter provides guidance for the design of ground products (gasoline, diesel)

fueling facilities and covers government vehicle motive fuel filling stations and tactical 

refueler truck loading facilities. Private vehicle filling stations, such as exchange service 

stations, are not included.

7-1.1 Types of Facilities

The following three types of filling stations may be required (see Facility Plates 011, 012

and 013):

a) A filling station for dispensing motive fuel gasoline and diesel into 

government (commercial type) sedans, vans, and small trucks. See 

Facility Plate 011. 

b) A filling station for dispensing motive fuel gasoline and diesel into 

tactical vehicles. See Facility Plate 011. 

c) A truck loading facility for loading gasoline and diesel into tactical 

refueler vehicles. See Facility Plates 012 and 013. 

7-2 GENERAL REQUIREMENTS

Chapter 2, General Design Information, contains important information on fueling 

facilities. Do not start design of any fueling system without first becoming completely 

familiar with Chapter 2 of this UFC.

7-3 DESIGN REQUIREMENTS

7-3.1 Fuel Segregation

Provide separate receiving, storage and distribution systems for each grade or type of 

fuel. Except as otherwise approved by Service Headquarters, prevent misfueling 

(transferring a type of fuel other than the type intended) by using different size piping, 

valves, adaptors, nozzles, etc.

In the CONUS, use color coding in accordance with API RP 1637. In non-CONUS 

facilities, use host nation standard if it is different than API RP 1637. Use API RP 1637

if no other standard is in effect. For Air Force projects to refer to AFTO 37-1-1. 

7-3.2 Facility Size

In each filling station, provide one commercial-type dispensing unit which displays 

volume only for each 100 vehicles assigned to the activity. The total amount of storage 

capacity in each station should be approximately twice the capacity of all vehicle fuel 

tanks, by grade or type of fuel, assigned to the activity. Minimum storage capacity for 

any grade or type of fuel is 5,000 gallons (19 000 L) unless approved by Service 

Headquarters. For tactical refueler truck loading facilities, see Chapter 3 of this UFC.
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7-3.3 Facility Configurations

In general, for control and safety, separate the three types of filling stations. For a 

relatively small installation or one on which there is a limited amount of activity expected 

at one time, it may not be practical to provide totally separate facilities. In those cases, 

separate the functions as much as possible to minimize mixing traffic of commercialtype vehicles from tactical vehicles and, more importantly, from mixing tactical refuelers

which are being loaded with relatively large quantities of fuel from other vehicles which 

are being fueled for their own engine (motive fuel).

7-3.4 Shelters

For staffed facilities, provide a shelter for personnel, records, and tools.

7-3.5 Concrete Fueling Area – Filling Stations

Create a fueling area constructed of concrete by surrounding fueling islands with a 

concrete slab graded at a minimum of 1 percent away from the islands. 

7-3.6 Concrete Fueling Area – Tactical Refueler Truck Loading Facilities

Provide concrete spill containment areas and concrete remote spill containment 

systems as described for truck loading facilities in Chapter 3 of this UFC.

7-3.7 Canopies

7-3.7.1 Canopies to Protect Fixed Assets

Provide a canopy for protection from the elements of fixed facility assets and equipment

unless otherwise directed by Service Headquarters. Fixed facility assets and equipment 

include but are not limited to: pump pads, filtration pads, meter pads, isolation valve 

pads, off-loading and loading equipment pads, control panels, electrical panels, and 

motor control centers (MCCs). Ensure structural design is in accordance with UFC 1-

200-01 and UFC 3-301-01. 

7-3.7.2 Canopies to Reduce Stormwater at Tactical Refueler Truck Loading 

Facilities

Do not provide a canopy to preclude rain from reaching the containment area unless it 

is required by federal, state, or local regulations; or it is economically justified by 

reducing the size of the concrete remote spill containment or spill treatment system; or if 

directed by Service Headquarters. Ensure that the underside of the canopy is high 

enough to provide operator head room when walking on top of the truck. Ensure 

structural design is in accordance with UFC 1-200-01 and UFC 3-301-01. 

7-3.7.3 Canopies to Reduce Stormwater of Filling Stations

Do not provide a canopy to preclude rain from reaching the concrete fueling area unless 

it is required by federal, state, or local regulations; or a concrete remote spill 

containment or treatment system is required by federal, state, or local regulations and it 

is economically justified by reducing the size of the remote spill containment or spill 

treatment system; or if directed by Service Headquarters. Ensure structural design is in 

accordance with UFC 1-200-01 and UFC 3-301-01. 
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7-3.8 Regulations

Design must comply with NFPA 30, NFPA 30A, and API RP 1615. 

7-3.9 Bottom Loading

The bottom loading of refuelers is required if the refuelers are equipped for it. However, 

there are Army refuelers which are not equipped for bottom loading and which will be in 

inventory for several years. Therefore, consult Service Headquarters before providing 

top loading at tactical refueler fillstands.

7-4 STORAGE TANKS

Chapter 8, Atmospheric Storage Tanks, contains information on aboveground and 

underground storage tanks. For ground products fueling facilities underground, 

horizontal tanks are preferred. Follow federal, state, and local regulations when 

determining use of AST or UST. 

7-5 PIPING SYSTEMS

7-5.1 Piping System – Tactical Refueler Facilities

For systems serving tactical refueler fillstands see the requirements for tank truck 

loading facilities in Chapter 3 of this UFC.

7-5.2 Aboveground Piping System – Filling Stations

Follow state or local regulations when they exceed these requirements. When they do 

not exceed them, provide as described in Chapter 9 of this UFC with the following 

exceptions:

a) Piping 4 inches (100 mm) and larger shall be buttwelded or socket 

welded. Use flange connections for joining pipe to equipment.

b) Piping smaller than 4 inches (100 mm) may be buttwelded, or socket 

welded. Use flange connections, or socket weld connections with 

unions for joining pipe to equipment. Threaded end connections may 

be used only where buttwelded or socket welded connections cannot 

physically be provided. 

c) Branch outlet fittings do not have to be designed to be radiographed. 

7-6 EQUIPMENT DESCRIPTIONS

7-6.1 Filling Stations 

7-6.1.1 Fuel Dispensers

Use a commercially available dispenser with a self-contained electric motor and 

pumping unit or a remote pumping type where the pump and motor are located in the 

storage tank. If an in-tank type of pump is used, ensure that it is equipped with a 

reduced start volume as a leak check. Provide a meter for each dispenser. Dispenser 

flow rates are typically a maximum of 10 gpm (0.6 L/s); follow state and local regulations 

for actual maximum. Designer shall check with state and local regulations for limitations 
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on dispenser flowrates. Dispensing system will include management control system, 

printers, computers, and microprocessors. Equip fuel dispensers with an inline filtration 

system capable of sediment removal to 10 mg/L or less. Add emergency break-away 

hose connections at each fuel dispenser in accordance with NFPA 30A. Where liquid is 

supplied to the dispenser under pressure, provide an emergency shutoff valve, 

incorporating a fusible link, in the supply line at the base of each dispenser as required 

by NFPA 30A. Equip dispensing islands with impervious spill containment pans under 

the dispensers. 

7-6.1.2 Card and Key Locks

Consider the possible economic and operational advantages of using an electronic card 

or key system which permits 24-hour unmanned operation of the facility. These types of 

systems are comprised of a card/key reader which is located near the service pump. 

The reader is activated by a card or key and accumulates issues and customer data 

which is downloaded to a central computer on a periodic basis. Activities with 

capitalized fuel, that is petroleum product owned by DLA/DESC, are eligible for projects 

to install automated card/key lock systems. Activities with capitalized fuel report 

inventories of these products to DESC through a system called BSM-E. Automated 

systems to control capitalized inventories must be able to interface with the BSM-E. 

These types of automated systems are managed under the AFSS program by DESC. It 

should be noted that AFSS equipment is used to control issues of product and is not an 

automated tank gauging system. Further information on AFSS systems and funding 

programs may be obtained by contacting DES-Energy.

7-6.2 Tactical Refueler Truck Loading Facilities

Equip similar to truck loading facilities covered in Chapter 3 of this UFC except provide 

a grounding reel in lieu of the high-level shutoff/ground detecting system. Verify the 

type of nozzle required by the user.

7-6.3 Valves

For systems serving tactical refueler fillstands see the requirements for tank truck 

loading facilities in Chapter 3 of this UFC. The below requirements apply to filling 

station only.

7-6.3.1 Materials of Construction

Require valves to have carbon steel bodies and bonnets. Do not allow valves with 

aluminum, cast iron, or bronze materials. Use only API fire-safe valves.

7-6.3.2 Isolation Valve Types

a) Ball Valves: These are the only approved quick opening/frequent 

opening isolation valves. Ball type, lockable, valves designed so that if 

the synthetic seating material is burned out in a fire, a metal-to-metal 

seat will remain to affect closure and comply with API Std 607. Use 

Teflon or Viton synthetic seals or seating material. Valves should 

comply with API Std 608. 
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b) Double Block and Bleed Isolation Valves: Do not provide unless 

directed by Service Headquarters. 

c) Lubricated Plug Valves: Lubricated plug valves are not allowed.

d) Gate Valves: Gate valves are not allowed.

e) Butterfly Valves: Butterfly valves are not allowed.

7-6.3.3 Isolation Valve Operators

Manually operate valves not specified for remote, automatic, or emergency operation. 

Use geared operators for ball valves larger than 6 inches (150 mm). Provide locking 

tabs on isolation valves to allow padlock to be used to lock out the valves during 

maintenance. Provide chain operators on valves which are located 72 inches (1800 

mm) or higher above grade.

7-6.3.4 Isolation Valve Locations

Provide isolation valves in piping systems to control flow and to permit isolation of 

equipment for maintenance or repair, or as necessary to conduct a valid hydrostatic 

test. As a minimum requirement, provide isolation valves at the following locations:

a) Where piping goes underground or comes aboveground and requires 

periodic pressure testing.

b) At all subsurface and aboveground piping connections to storage 

tanks. 

c) On the suction side and discharge side of each pumping unit, except 

the suction side of vertical centrifugal pumps installed in underground 

tanks. 

d) On the inlet and outlet connection of each line strainer, meter, 

diaphragm control valve, and other equipment that requires periodic 

servicing. One inlet valve and one outlet valve may be used to isolate 

more than one piece of adjacent equipment which are connected in 

series. 

7-6.4 Diaphragm Control Valves

These valves are not required in filling stations. 

7-6.5 Other Valves

7-6.5.1 Check Valves

Use check valves to prevent backflow through pumps, branch lines, meters, or other 

locations where runback or reverse flow must be avoided. Check valves may be of the 

swing disk, globe, dual plate hinged disk, spring-loaded poppet, ball, or diaphragmactuated types. Use checks of soft-seated non-slamming type with renewable seats 

and disks. Ensure check valves conform to API Spec 6D. 
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7-6.5.2 Thermal Relief

Provide thermal relief valves around isolation and check valves to relieve excessive 

pressures caused by thermal expansion of liquid trapped between shutoff points. See 

Facility Plates 023, 024, 025 and 026. 

7-7 VAPOR RECOVERY

Provide vapor recovery in accordance with guide specifications unless there are more 

stringent federal, state, and local codes or regulations. Some requirements are in 40 

CFR Part 60 Subpart XX. If gasoline is being handled, provide, as a minimum, Stage I 

vapor recovery and the piping for Stage II. If Stage II is not required by local or state 

regulations at time of installation, cap the vapor return pipe at the dispenser.
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CHAPTER 8 - ATMOSPHERIC STORAGE TANKS

8-1 INTRODUCTION

This chapter provides guidance for the design of bulk storage tanks, operating storage 

tanks, ground vehicle fueling tanks, miscellaneous use tanks, product recovery system 

tanks, contaminated fuel storage tanks, and jet engine test cell fuel storage tanks. 

Design guidance on issues related to storage tanks such as protection, location, 

coatings, product recovery, and spill containment systems are also covered in this 

chapter. Ballast water storage tanks are covered in Chapter 5 and pressurized tanks for 

storage of LPG are covered in Chapter 10 of this UFC. This chapter generally applies 

to new tanks. Refer to Chapter 12 for repair or refurbishment of existing tanks.

8-2 GENERAL REQUIREMENTS

Chapter 2, General Design Information, contains important information on fueling 

facilities. Do not start design of any fueling system without first becoming completely 

familiar with Chapter 2 of this UFC.

8-3 GENERAL CRITERIA

Design liquid fuel storage tanks to comply with the operational requirements of the 

particular command having jurisdiction of the facility. Ensure that the design is 

appropriate for the mission of the facility. Consider the operational requirements of the 

users of the fuel.

8-3.1 Materials

All aboveground storage tanks shall be constructed of steel or concrete encased steel.

8-3.2 Protection

Provide protection to preserve product quality and ensure minimal losses by 

evaporation, dilution, leakage, substitution, theft, contamination, attack, sabotage, fire, 

and damage to the environment. Use aboveground steel tanks unless the mission of

the facility or other practical considerations dictate that underground tanks be used. Cut 

and cover (buried vertical) tanks are not normally used in the CONUS. Cut and cover

tanks may be required if the dispensing system is located in clear zones or explosive 

cordon areas. Conduct economic, operational, and mechanical analyses of remotely 

locating the pump house/system from the hydrant system versus constructing cut and 

cover tanks.

8-3.3 Design Requirements

Fuel storage facilities provide an operating and reserve supply of fuel. The types and 

sizes of storage tanks depend on safety, economics, terrorist activity, locality, and 

intended service. Provide separate storage for each type and grade of fuel. For 

aviation activities, provide a minimum of two tanks for each type of fuel.

8-3.4 Storage Capacity

The capacity or size of each fuel storage tank is based upon the logistical and mission 

requirements for the facility and any other facility to be supported from it. For a stated 

volume of each fuel, fewer tanks of larger size will result in maximum economy. The 
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appropriate Service Headquarters with DESC/DLA approval will determine the number 

and size of tanks required. Rule of thumb guidance for operating storage and bulk 

storage capacity is available in Navy UFC 2-000-05N/P-80. Provide a minimum of two 

tanks at aviation activities for each type of aviation turbine fuel to receive and isolate 

new receipts until tested and checked for quality and quantity while the facility continues 

to function with stocks on hand. In general, capacities of individual tanks should not 

exceed 50 percent of the total storage volume required for each type and grade of fuel. 

Do not provide tanks with capacities greater than 100,000 barrels (16 000 m3) except 

when larger tanks are specifically authorized by Service Headquarters.

8-3.5 Tank Spacing

8-3.5.1 Vertical Tanks

Provide a minimum distance between the shells of vertical tanks, both aboveground and 

underground, of not less than one diameter of the larger tank.

8-3.5.2 Horizontal Underground Tanks

Provide a minimum clearance between shells of adjacent horizontal underground tanks 

of 3 feet (0.9 m). 

8-3.5.3 Horizontal Aboveground Tanks (Single-Wall and Double-Wall Steel) 

(Non-Fire Resistant and Non-Protected)

Provide a minimum clearance between aboveground horizontal tanks with capacities 

40,000 gallons (151 400 L) or under as follows:

a) Arrange tanks in pairs with a minimum of 5 feet (1.5 m) between tanks 

in each pair and 10 feet (3 m) between adjacent tanks of two pairs in 

the same row.

b) Space adjacent groups of more than two pairs in a single row with at 

least 20 feet (6 m) between the nearest tanks of the groups.

c) Provide a minimum end-to-end spacing between tanks in longitudinal 

rows of 20 feet (6 m).

d) Provide a UL nameplate on tanks stating that the tanks are approved 

for that material and service. 

e) In addition to requirements listed in this paragraph, tanks located in 

facilities governed by NFPA 30A, such as marine/motor fuel dispensing 

facilities, shall comply with NFPA 30A. 

8-3.5.4 Horizontal Aboveground Tanks (Fire Resistant) 

Provide minimum clearance and spacing between fire resistant, secondarily contained

aboveground horizontal tanks in compliance with NFPA 30 and NFPA 30A as 

applicable. 
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8-3.5.5 Horizontal Aboveground Tanks (Protected) 

Provide minimum clearance and spacing between protected, secondarily contained 

aboveground horizontal tanks in compliance with NFPA 30 and NFPA 30A as 

applicable. 

8-3.6 Distance from Buildings and Property Lines

Locate tanks a sufficient distance from buildings and property lines to prevent the 

ignition of vapors from the tank and to protect buildings and their occupants or contents 

from damage by a tank fire. Assume that the maximum internal pressure in a fire 

exposure will not exceed 2.5 psig (17 kPa). As a minimum, comply with requirements of 

the following paragraphs.

8-3.6.1 Underground Tanks

Locate underground tanks with respect to buildings or similar structures so that the soil 

pressure created by the building foundations will not be transmitted to the tank. 

Pumping facilities which are often located directly above underground tanks are 

accepted. Locate horizontal cylindrical tanks less than or equal to 12 feet (3.7 m) in 

diameter not less than 10 feet (3 m) from the nearest point of an adjacent building or 

property line. Locate vertical underground tanks at least 25 feet (7.6 m) from the 

nearest point of an adjacent building and 50 feet (15 m) from the nearest property line.

8-3.6.2 Aboveground Tanks

Locate aboveground tanks with consideration of fire safety. The first consideration is to 

prevent the ignition of vapors from the tank, and the second consideration is to protect 

the building and its occupants or contents from damage by a tank fire. As a protective 

measure, provide all aboveground tanks with some form of emergency relief venting for 

fire exposure in accordance with NFPA 30. In the following, it is assumed that all tanks 

are constructed or equipped so that the maximum internal pressure in a fire exposure 

will not exceed 2.5 psi (17 kPa). Recommended minimum distances for aboveground 

tanks from buildings and property lines are as follows:

a) Tanks, all sizes and types, not protected or fire-resistant, containing 

petroleum fuels with a flash point less than 100 degrees F (38 degrees 

C), 100 feet (30 m) or one tank diameter, whichever is greater. Tanks 

located in facilities governed by NFPA 30A, such as marine/motor fuel 

dispensing facilities, shall comply with NFPA 30A. 

b) Tanks, not protected or fire-resistant, containing petroleum fuels with a 

flash point of 100 degrees F (38 degrees C) or greater in accordance 

with the following:
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Tank Capacity

gallons (L)

Minimum Distance from 

Nearest Property Line

Feet (m)

Minimum Distance from

Nearest Building

Feet (m)

275 or less (1040 or less) 10 (3.0) 5 (1.5)

276 to 750 (1041 to 2800) 20 (6.0) 10 (3.0)

751 to 12,000 (2801 to 45 400) 30 (10) 15 (4.5)

12,001 to 30,000 (45 401 to 113 500) 40 (12) 20 (6.0)

30,001 to 50,000 (113 501 to 189 000) 60 (18) 60 (18)

50,001 to more (189 001 or more) 100 (30) 100 (30)

c) For aboveground, fire-resistant tanks in facilities governed by NFPA 

30A, use NFPA 30A guidelines.

d) For aboveground, protected tanks, use NFPA 30 guidelines. Protected 

tanks located in facilities governed by NFPA 30A, such as 

marine/motor fuel dispensing facilities, shall comply with NFPA 30A. 

8-3.7 Distance from Roadway, Railroads and Power Lines

Minimum distances of storage tanks from adjacent roadways, railways, railroads, and 

overhead electric power lines are as follows:

8-3.7.1 Underground Tanks

Locate underground tanks with respect to buildings or similar structures so that the soil 

pressure created by the building foundations will not be transmitted to the tank. 

Pumping facilities which are often located directly above underground tanks are 

accepted. Spacing and clearances for underground tanks shall be in accordance with 

the most conservative of NFPA 30, NFPA 30A, or as follows: 

a) A minimum of 25 feet (7.6 m) from regularly traveled roads and 

highways, not including tank farm utility and fire access roads.

b) 25 feet (7.6 m) from railroad spur tracks not used for through traffic.

c) No less than 100 feet (30 m) from main railroad tracks carrying through 

traffic.

d) 50 feet (15 m) from overhead electric power transmission and 

distribution wires.

8-3.7.2 Aboveground Tanks

a) The greater of 100 feet (30 m) or one tank diameter from regularly 

traveled roads and highways, not including tank farm utility and fire 

access roads.

b) 50 feet (15 m) from railroad spur tracks not used for through traffic.

c) 200 feet (60 m) from main railroad tracks carrying through traffic.
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d) 50 feet (15 m) from overhead electric power transmission and 

distribution wires.

e) For above-ground, fire-resistant tanks in facilities governed by NFPA 

30A, use NFPA 30A guidelines.

f) For above-ground, protected tanks, use NFPA 30 guidelines. 

Protected tanks located in facilities governed by NFPA 30A, such as 

marine/motor fuel dispensing facilities, shall comply with NFPA 30A. 

8-3.8 Distance from Tank Truck and Tank Car Off-Loading and Loading

Facilities

Provide a minimum distance between both aboveground and underground storage 

tanks of not less than 50 feet (15 m) from tank truck and tank car off-loading and 

loading facilities.

8-3.9 Interior Coatings

To extend the life of steel storage tanks, coat new tanks according to the following 

guidelines: 

a) Vertical tanks

(1) All aviation, diesel fuel marine (F-76), additive, and lube oil tank. 

Interiors shall be 100 percent coated, including floor, shell, and 

underside of the roof.

(2) Other products. Coat the floor, the underside of the fixed roof, 

and the bottom 40 inches (1000 mm) of the tank shell. 

Additional coating of up to 100 percent requires economic 

justification and Service Headquarters approval.

b) Horizontal tanks

(1) For all products, tank interiors shall be 100 percent coated.

c) For all products coat the interior and exterior of carbon steel piping 

located inside the tank, and steel appurtenances inside all tanks.

8-3.10 Exterior Coatings

a) Protect the exterior surface of all aboveground steel tanks by coating in 

accordance with appropriate guide specifications.

b) Protect the exterior surfaces of all underground horizontal steel tanks 

with a factory-applied coating specified in the appropriate guide 

specifications. 
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c) For protected tanks, with exterior steel containment, consider exterior 

fiberglass cladding for extremely corrosive atmospheres or seaside 

locations.

8-3.11 Fill Piping

Size the pipe so that the velocity does not exceed 12 feet (3.7 m) per second at 

maximum flow rate. Provide a means for reducing the velocity of flow to 3 feet (0.9 m) 

per second until the filling inlet nozzle is completely submerged and/or the floating pan 

has lifted off its legs.

8-3.12 Vapor Emission Control Systems

Provide a vapor emission control system for tanks that store products having a true 

vapor pressure of 0.75 psia (5 kPa) or more located in air pollution control areas in 

which the discharge of petroleum vapors is controlled or prohibited. Ensure that the 

system has sufficient capacity to control the vapor discharged from the tank vents at 

maximum filling rate in conformance with local air quality regulations. If gasoline is 

being handled, provide, as a minimum, Stage I vapor recovery and the piping for Stage 

II. If not required by local or state regulations at time of construction, connect the Stage 

II piping to the tank and cap it at the dispenser.

8-3.13 Strapping Tables

Provide API MPMS 2 certified strapping tables for all tanks. A registered Professional 

Engineer must approve strapping tables. Use 1/16-inch (2 mm) increments reading in 

gallons. Provide electronic media data files. Determine strapping table volumes using 

physical measurements, not calculated values. 

8-3.14 Product Recovery Systems

8-3.14.1 General Design Considerations

Provide pumps, piping, valves, and tanks to collect and store usable aviation turbine 

fuel which would otherwise become waste from operational or maintenance activities. 

Consider a product recovery system for other products. Include a tank to collect 

fuel/water mixtures from tank and equipment sumps, equipment drains, product saver 

tanks, high point vents, low point drains, and any other equipment from which fuel/water 

mixtures can be collected. Separate the fuel and water portions. Filter the fuel portion 

and return to operating storage tanks. Do not discharge the water portion to surface 

water without additional treatment and permits or treat the water portion as wastewater. 

Refer to Chapter 2 of this UFC for information on handling of wastewater. Refer to DoD 

Standard Design AW 78-24-28. These systems are standard with the hydrant and 

aircraft direct fueling systems. 

8-3.14.2 Product Recovery Tanks

For hydrant and aircraft direct fueling systems provide the tank indicated in DoD 

Standard Design AW 78-24-28. For other systems, provide a tank with, at a minimum, 

the following appurtenances:

a) Level gauge.
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b) Overfill protection level control valve.

c) High and low level switches with alarms and controls. 

d) A motor driven fuel transfer pump that returns recovered fuel back to 

the system through a hard piped connection. 

e) A motor driven sump pump for emptying the tank.

f) Manual gauging hatch.

g) Vent.

h) ATG system for aboveground product recovery tanks having a capacity 

more than or equal to 4,000 gallons (15 000 L). 

i) Do not allow sight flow indicators to be installed on product recovery 

tanks. 

8-3.14.3 Vertical Storage Tanks 

In addition to the product recovery tank(s) for the facility, all vertical storage tanks 

storing aviation turbine fuel should include a product saver tank with electric pump, 

unless the tank is equipped with a filter/separator to remove water from the sump. A 

product saver tank is a small aboveground tank piped and valved to allow drawing water 

from the bottom of the storage tank and returning the product after the water has been 

separated and disposed of in accordance with environmental regulations. 

8-3.15 Registration

Register all tanks with the appropriate state and local agencies as required. All tanks 

shall have a nameplate installed in accordance with API Std 650. 

8-4 HORIZONTAL ABOVEGROUND TANKS (SINGLE-WALL STEEL)

8-4.1 General Design Considerations

If small factory-built aboveground storage tanks are required, use horizontal tanks. 

Limit tank diameter to 12 feet (3.7 m) or less and capacity to less than 50,000 gallon

(191 m3). Require tank to be of welded steel construction in accordance with UL 142. 

Plastic and/or fiberglass aboveground storage tanks are not allowed. Requirements for 

all horizontal aboveground storage tanks shall comply with NFPA 30 Chapter 22

Aboveground Storage Tanks. Tanks located in facilities governed by NFPA 30A, such 

as marine/motor fuel dispensing facilities, shall comply with NFPA 30A. 

8-4.2 Installation

a) Install the tank so that the bottom slopes downward toward one end at 

a slope of 1 percent. Locate transfer pumps or suction piping at the 

high end of the tank; locate water drawoff at low end of the tank.
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b) Provide protective bollards for tanks not surrounded by a dike. 

c) Provide water drawoff lines in each tank. For aviation fueling systems, 

arrange piping so that the fuel in the tanks may be recirculated through 

the filter/separators. Refer to Facility Plate 018. 

d) Provide steel tanks with steel saddles or skids in accordance with UL 

142. The bottom of tank is to be at least 12 inches (300 mm) above 

grade to avoid the need for fireproofing. Mount steel supports on a 

reinforced concrete foundation.

e) Require tanks to be inspected by a STI Registered Inspector with Level 

1 and 2 Certification prior to the tanks being put into service.

8-5 HORIZONTAL ABOVEGROUND TANKS (DOUBLE-WALL STEEL)

8-5.1 General Design Considerations

Limit tank diameter to 12 feet (3.7 m) or less and capacity to less than 50,000 gallon

(191 m3

). Require tank to be of welded steel construction in accordance with UL 142. 

No fiberglass aboveground storage tanks are allowed. The main advantage of doublewall steel storage tanks over single-wall steel storage tanks is that separate spill

containment may not be required. NFPA 30 and NFPA 30A have specific criteria for 

omitting spill containments when using this type of secondary containment-type tank. 

All of the criteria in the NFPA regulations for the appropriate application must be met 

before this type of tank is used without spill containment. Requirements for double-wall 

steel horizontal aboveground storage tanks shall comply with NFPA 30 Chapter 22

Aboveground Storage Tanks. Tanks located in facilities governed by NFPA 30A, such 

as marine/motor fuel dispensing facilities, shall comply with NFPA 30A. 

8-5.2 Installation

a) For flammable liquid installations, require additional curbing 

containment based on tank filling rates if there is a chance of a fuel 

spill entering a critical area.

b) Install the tank so that the bottom slopes downward toward one end at 

a slope of 1 percent. Locate transfer pumps or suction piping at the 

high end of the tank; locate water drawoff at low end of the tank. 

c) Provide water drawoff lines in each tank. For aviation fueling systems, 

arrange piping so that the fuel in the tanks may be recirculated through 

the filter/separators. 

d) Provide protective bollards for tanks not surrounded by a dike. 

e) Provide steel tanks with steel saddles or skids in accordance with UL 

142. The bottom of tank is to be at least 12 inches (300 mm) above 
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grade to avoid the need for fireproofing. Mount steel supports on a 

reinforced concrete foundation.

f) Require the tank to be pressure-tested after installation.

g) Require tanks to be inspected by a STI Registered Inspector with Level 

1 and 2 Certification prior to the tanks being put into service.

8-6 HORIZONTAL ABOVEGROUND TANKS (FIRE-RESISTANT) 

8-6.1 General Design Considerations

When small (250 to 20,000 gallon (900 to 75 000 L) capacity) aboveground storage 

tanks are required and there are clearance or fire exposure problems and the additional 

cost can be justified, consider the use of fire-resistant storage tanks. The main 

advantage of fire-resistant tanks over the single wall steel tanks is that separate spill 

containment may not be required and the vault system provides an added measure of 

fire protection. NFPA 30 and NFPA 30A have specific criteria for omitting spill 

containment when using this type of secondary containment-type tank. All of the criteria 

in the NFPA regulations for the appropriate application must be met before this type of 

tank is used without spill containment. Require tanks to be factory-constructed with a 

UL 142 welded steel primary tank, generally low profile and rectangular in design. 

Tanks may be used in applications where, in addition to the above considerations, 

construction of a separate spill containment system for secondary containment 

purposes would have a negative impact on operations and/or aesthetics. Tanks located 

close to buildings or with integral fuel dispensers must be UL-listed secondary 

containment tanks, utilizing steel inner and outer tanks that can provide interstitial 

containment which is both pressure testable and verifiable. Such tanks usually have a 

fill of regular or insulating concrete. Ensure the two-hour fire rating meets or exceeds all 

requirements of NFPA 30A for “fire resistance” tanks, meets the requirements of UFC 3-

600-01 and provides a minimum two-hour fire rating in accordance with UFC 3-600-01

and UL 2080.

8-6.2 Installation

a) For flammable liquid installations, require additional curbing 

containment based on tank filling rates if there is a chance of a fuel 

spill entering a critical area.

b) Install the tank so that the bottom slopes downward toward one end at 

a slope of 1 percent. Locate transfer pumps or suction piping at the 

high end of the tank; locate water drawoff at low end of the tank.

c) Provide water drawoff lines in each tank. For aviation fueling systems, 

arrange piping so that the fuel in the tanks may be recirculated through 

the filter/separators. 

d) A primary tank of stainless steel can be allowed as an option to interior 

coated carbon steel for all applications where economically justified.
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e) Require support channels with anchor holes for 

earthquake/hurricane/flood restraint tie down.

f) Require steel to be a minimum thickness of 3/16-inch (5 mm) for the 

interior carbon steel tank.

g) Provide protective bollards in traffic areas.

h) Require the tank to be pressure-tested after installation.

i) Require tanks to be inspected by a STI Registered Inspector with Level 

1 and 2 Certification prior to the tanks being put into service.

8-7 HORIZONTAL ABOVEGROUND TANKS (PROTECTED TANKS) 

8-7.1 General Design Considerations

When small (250 to 20,000 gallon (900 to 75 000 L) capacity) aboveground storage 

tanks are required and there are clearance or fire exposure problems and the additional 

cost can be justified, consider the use of protected storage tanks. The main advantages 

of protected tanks over the single wall steel tanks are that a separate dike (containment) 

may not be required and the vault system provides an added measure of fire protection. 

NFPA 30 and NFPA 30A have specific criteria for omitting dikes when using this type of

secondary containment-type tank. All of the criteria in the NFPA regulations for the 

appropriate application must be met before this type of tank is used without a dike. 

Additional benefits include added protection from ballistic and vehicular impact and 

reduced evaporation of volatile fuels in warm climates. Require tanks to be factoryconstructed with a UL 142 welded steel primary tank, generally low profile and 

rectangular in design. Tanks may be used in applications where, in addition to the 

above considerations, construction of a separate dike for secondary containment 

purposes would have a negative impact on operations and/or aesthetics. Tanks located 

close to buildings or with integral fuel dispensers must be UL-listed secondary 

containment tanks, utilizing steel inner and outer tanks that can provide interstitial 

containment which is both pressure testable and verifiable. Such tanks usually have a 

fill of regular or insulating concrete. Ensure the two-hour fire rating meets or exceeds all 

requirements of NFPA 30A for “fire resistance” tanks, meets the requirements of UFC 3-

600-01 and provides a minimum two-hour fire rating in accordance with UFC 3-600-01

and UL 2085.

8-7.2 Installation

a) For flammable liquid installations, require additional curbing 

containment based on tank filling rates if there is a chance of a fuel 

spill entering a critical area.

b) Install the tank so that the bottom slopes downward toward one end at 

a slope of 1 percent. Locate transfer pumps or suction piping at the 

high end of the tank; locate water draw-off at low end of the tank.
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c) Provide water drawoff lines in each tank. For aviation fueling systems, 

arrange piping so that the fuel in the tanks may be recirculated through 

the filter/separators. Locate the water drawoff piping at the low end of 

the tank.

d) For applications not requiring secondary containment, such as 

residential heating oil tanks where aesthetics may be the prime 

concern, consider protected, exposed aggregate, tanks with a UL 2085

secondary containment protected rating without the outer steel jacket.

e) A primary tank of stainless steel can be allowed as an option to interior 

coated carbon steel for all applications where economically justified.

f) Require support channels with anchor holes for 

earthquake/hurricane/flood restraint tie down.

g) Require steel to be a minimum thickness of 3/16-inch (5 mm) for the 

interior carbon steel tank. 

h) Provide protective bollards in traffic areas.

i) Require the tank to be pressure-tested after installation.

j) Require tanks to be inspected by a STI Registered Inspector with Level 

1 and 2 Certification prior to the tanks being put into service.

8-8 ABOVEGROUND VERTICAL STORAGE TANKS

8-8.1 General Design Considerations

Provide cylindrical single-wall steel aboveground vertical storage tanks meeting one of 

the following criteria (as approved by Service Headquarters):

a) Factory-fabricated tanks complying with UL 142 criteria. The diameter 

of the tanks is limited by transportation restrictions. Although these 

tanks are fabricated in sizes up to 50,000 gallon (191 m3), they 

become quite tall due to the diameter limitation. Give special 

consideration to height/diameter ratio to ensure tank stability.

b) Field-erected tanks not requiring an internal pan follow API Std 650

configured as required by this UFC. 

c) Field-erected tanks complying with DoD Standard Design AW 78-24-

27. The standard design includes tanks ranging in capacity from 2,500 

barrels (400 m3) through 100,000 barrels (16 000 m3) with internal pan 

and requires site-adapting by the design team. For tanks larger than 

100,000 barrels (16 000 m3

), use the multicolumn API Std 650 design. 
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d) Require tanks to be inspected by a STI Registered Inspector with Level 

1 and 2 Certification or an API Std 653 Certified Inspector, where 

applicable, prior to the tanks being put into service.

8-8.2 Tank Roofs

For tanks with internal floating pans, design the roofs in conformance with DoD 

Standard Design AW 78-24-27.

8-8.3 Internal Floating Pans

a) Tanks containing Class I flammable fuels or mission-critical Class II 

combustible fuels, such as JP-8, shall be equipped with a full contact, 

aluminum honeycomb floating pan. Other Class II fuels require a 

floating pan if the tank does not comply with the spacing and diking 

requirements of this UFC. Tanks storing mission-critical Class III fuels, 

such as JP-5 and diesel fuel marine (F-76), if located in hot (desertlike) climate, also require a floating pan to eliminate the fuel/air 

interface. A single slotted stilling well, that penetrates the floating pan, 

has a maximum diameter of 10 inches (250 mm) and is used for the 

automatic tank gauge system, is allowed to be provided without a 

vapor sleeve (bellow). The slotted well used for manual 

measurements shall be equipped with an approved floating plug.

b) For cone roof tanks with floating pans, provide roof vent/inspection 

hatches in the fixed roof and overflow port/vents near the top of the 

shell near a device(s) in the floating pan which is (are) sized by the 

manufacturer to evacuate air and gases from underneath the pan 

when the pan is on its supports during filling operations.

c) Provide grounding bonds between the floating pan and shell as 

follows:

(1) Three lengths of bare, 3/16-inch (5 mm) diameter, stranded, 

extra-flexible, stainless steel wire rope, each extending from the 

top of the floating pan to the underside of the fixed roof.

(2) Attach two of the wires near the tank periphery, 180 degrees 

apart. Attach the third wire to the floating pan manhole cover.

(3) Securely connect the wires to the pan and extend vertically to 

the tank roof. Ensure wires are accessible for inspection.

(4) Ensure wires are long enough to accommodate the full travel of 

the pan. Locate wires to miss all interior tank appurtenances 

and structure.

d) Provide anti-rotation cables in accordance with DoD Standard Design 

AW 78-24-27. 
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e) For cone roof tanks with floating pans, provide gauge and sampling 

hatches in accordance with DoD Standard Design AW 78-24-27. 

f) Provide a 36-inch (900 mm) diameter covered manhole in the floating 

pan.

8-8.4 Tank Bottoms

Slope the tank bottoms downward in accordance with DoD Standard Design AW 78-24-

27. A slope of 5 percent is required for positive drainage and self-cleaning action for 

tanks storing aviation turbine fuels. After tank construction is complete perform a 

hydrostatic test; a helium test may be included as an option. Perform these tests prior 

to tank coating. Conduct all tests as recommended by API Std 650.

8-8.5 Foundations

Design tank foundations on the basis of a soils exploration program including 

preliminary exploration as a minimum and detailed exploration and testing, if existing 

soil data is not available and/or inadequate. Refer to UFC 3-220-10N. Analyze the 

results of the exploration program to determine the most practical and economical 

design to provide a stable foundation for the tank. See DoD Standard Design AW 78-

24-27. As a minimum, use the following criteria for all tank designs:

a) Prevent external corrosion of tank bottoms by locating the tanks well 

above the general tank field grade, provide adequate tank field 

drainage away from the tank, and construct the foundation pad of 

clean, free-draining granular material. If sand is used, ensure a 

minimum electrical resistance of 50,000 ohm-cm. Foundation material 

should be neutral or alkaline with a pH greater than 7, a chloride 

concentration less than 300 ppm, and a sulfate concentration less than 

150 ppm as specified by DoD Standard Design AW 78-24-27. The 

sand may be washed and the pH may be raised to meet the 

requirements. Include cathodic protection to prevent external 

corrosion of the tank bottoms. Do not use oil in the sand under the 

tank. Do not use dredge material or beach sand.

b) Provide good drainage under the tank.

c) Provide a reinforced concrete ringwall foundation and secondary 

containment. Locate the tank bottom a minimum of 12 inches 

(300 mm) above the dike basin.

d) Cover the area beneath the tanks with a dike fuel-impermeable liner 

complying with DoD Standard Design AW 78-24-27 and meeting local 

and state requirements. Install all liners according to the 

manufacturer's requirements.

e) Over the liner, provide a minimum of 12 inches (300 mm) of 

compacted clean sand or similar material as described above. 
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Securely attach and seal the liner to the inside of the concrete 

foundation ring wall beneath the tank shell.

f) Provide a leak detection system for the tank bottom by installing a pipe 

or pipes through the concrete foundation ring wall as a telltale for tank 

bottom leaks in accordance with DoD Standard Design AW 78-24-27. 

These pipes will also permit water beneath the tank to escape by 

gravity. 

g) Perform subsurface investigation in sufficient detail to determine if any 

compressible, weak, organic, or otherwise objectionable soils exist 

within a distance of two tank diameters below ground surface.

h) Estimate the magnitudes and rates of settlement (uniform, differential, 

and seismic induced) as part of the design. Provide adequate flexibility 

in piping, appurtenances, and other systems to accommodate 

anticipated settlements. Accomplish flexibility by using pipe offsets or 

ball joints. Do not use corrugated or bellows type expansion 

compensators. Do not exceed differential settlement values given in 

UFC 3-220-10N. 

i) Where objectionable materials exist or magnitudes of anticipated 

settlement are sufficient to cause damage or unacceptable distortion, 

consider subsurface improvement. Potential improvement techniques 

may include removal of objectionable materials and replacement with 

clean compacted granular fill, preloading or surcharging in conjunction 

with drainage wicks, deep dynamic compaction, vibrocompaction, 

stone columns, compaction grouting, or similar techniques.

j) Where justified by subsurface conditions and economics, consider 

using deep foundations such as driven piling or drilled shafts. Design 

foundation in accordance with UFC 3-220-01N. 

8-9 UNDERGROUND HORIZONTAL STORAGE TANKS

8-9.1 General Design Considerations

Where underground storage tanks of 50,000 gallon (191 m3

) or less capacity are 

required, use factory-built horizontal cylindrical double-wall tanks (welded steel or 

fiberglass reinforced plastic (FRP)). Ensure that contract requires the design and 

installation in accordance with 40 CFR Part 280 and NFPA 30 or any more stringent 

state or local criteria. Require separation of exterior tank walls from the interior walls 

with standoffs, thus creating an open space, or interstitial, for monitoring of leaks. This 

is called a Type II tank. Do not exceed 12 feet (3.7 m) in diameter for tanks. Limit tank 

length to eight times the diameter. Ensure that factory-fabricated tanks comply with UL 

58 and STI P3 criteria.
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8-9.2 Installation

a) Install tanks in accordance with NFPA 30 and also in strict accordance 

with the manufacturer's installation instructions.

b) Install the tank so that the bottom slopes downward toward one end at 

a slope of 1 percent. Locate transfer pumps and suction piping at the 

low end of the tank.

c) Provide straps and anchors designed to prevent flotation of tanks 

located in areas with high groundwater levels or subject to flooding. 

Provide electrical isolation strips between hold-down straps and metal 

tanks. Anchors may be a concrete anchor slab under the tank or 

concrete deadmen.

d) Place tanks on a uniform bed of homogeneous granular material at 

least 12 inches (300 mm) thick. If a concrete anchor slab is used, 

place a minimum of 6 inches (150 mm) of bedding for steel tanks and 

12 inches (300 mm) of bedding for fiberglass tanks between the tank 

and the concrete anchor slab. Do not use blocks, chocks, or rocks.

e) Ensure that tank is installed by state-certified contractor if state has a 

certification program.

f) Ensure that tank is installed by a contractor that is certified by the tank 

manufacturer.

8-10 UNDERGROUND VERTICAL STORAGE TANKS (Cut and Cover) 

8-10.1 General Design Considerations

Underground vertical storage tanks are steel-lined reinforced concrete with leak 

monitoring capability. These tanks may be completely buried, surface-constructed and 

then covered with embankment, or any variation in between. OCONUS Pacific they are 

only required in high threat areas or when tanks are required to be constructed within 

the explosive cordon area or clear zone. Tanks being constructed OCONUS NATO

refer to STANAG 3784 for design guidance. They are not used within CONUS except 

when tanks are required to be constructed within the explosive cordon. Design 

underground vertical steel storage tanks in accordance with DoD Standard Design AW 

78-24-27, except as modified herein. These standards include tank sizes of 10,000 

through 100,000 barrels (1600 m3 through 16 000 m3

) capacity. In general, do not 

exceed 100,000 barrels (16 000 m3) capacity. Alternative designs using 

prefabricated/pre-stressed tank sections must be approved by the appropriate Service 

Headquarters. Provide leak detection for underground storage tanks in accordance with 

federal, state, and local regulations.
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8-11 APPURTENANCES

Table 8-1 describes appurtenances for atmospheric storage tanks and identifies the 

type of tank to which they should be mounted. Full seal weld all tank attachments to 

prevent moisture/water from corroding the tank shell and attachments.

8-12 HEATERS

8-12.1 General Design Considerations

Provide tank heaters and controls for tanks intended for storage of high viscosity

products, such as lube oils, or burner fuels No. 4, No. 5, and No. 6, in climates where 

the ambient tank temperature would be less than 20 degrees F (11 degrees C) above 

the fuel’s pour point temperature. Heat heavy burner fuel oils and lube oils to a 

temperature of 20 degrees F (11 degrees C) above the fuel’s pour point prior to 

pumping. Use one of the types of heaters listed below.

8-12.2 Heating Medium

Use the appropriate heating medium for the particular application based on 

temperature, pressure, and availability. Saturated steam is the preferred heating 

medium, but consider using hot oil, hot water, and electric heating where steam is not 

available from existing sources.

8-12.3 Convection-Type

Use convection-type heaters installed inside a storage tank and capable of passing

through a 36-inch (900 mm) diameter manhole with a capacity to raise the temperature 

of a full tank of burner fuel oil approximately 60 degrees F (33 degrees C) in 24 hours. 

The appropriate Service Headquarters and/or DLA/DESC will determine if the capacity 

of the heater could be reduced if it is not necessary to heat a full tank of fuel within 24 

hours.

8-12.4 In-Line Type

In-line heaters consist of two general types: tank suction and straight tube. All in-line 

heaters are of the shell and tube construction. A tank suction or suction in-line heater is 

installed inside the tank on the tank issue line. The fuel oil enters the exchanger at the 

end within the tank and exits at the opposite end outside of the tank. The steam or 

other heating medium enters and exits the exchanger at the end outside of the tank. A 

straight tube or pipe in-line heater is installed directly into the pipeline. The fuel oil 

enters the exchanger at one end and exits from the other. The entry and exit points for 

the steam side can vary. The following criteria applies to in-line heaters: 

a) Capable of heating fuel oil passing through them from the ambient tank 

temperature to a minimum of 20 degrees F (11 degrees C) above the 

fuel oil’s pour point temperature at required flow rate.

b) If installed in tanks, allow removal of heater tube bundles without 

emptying the tank.

c) If multipass in-line heaters are used, do not allow the oil temperature 

rise to exceed 30 degrees F (17 degrees C) per pass.
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d) Use carbon steel shells designed for a minimum 175 psig (1210 kPa) 

cold working pressure on both steam and oil sides.

e) Do not exceed 0.2 psig (1.4 kPa) for the pressure drop on the oil side 

of pump suction line nor exceed 10 psig (70 kPa) of pressure drop for 

heaters installed on pump discharge.

8-12.5 Insulation and Tracing

In cases where fuels are heated, examine the possible economic incentives for 

insulating heated storage vessels and piping. In many cases, piping carrying heated 

products must be heat traced to prevent possible solidification of the fuel during a 

shutdown period. Insulate traced lines. Consider possible incentives for installing a 

condensate collection and return system. If a condensate return system is installed, 

include a monitor to detect oil in the condensate.

8-13 UNDERGROUND STORAGE TANK SPILL CONTAINMENT SYSTEMS 

8-13.1 General Design Considerations

Provide drainage structures to impound escaping fuel where rupture of an underground 

tank in a hillside location would endanger other activities and structures at elevations 

lower than the tank.

8-14 ABOVEGROUND TANK SPILL CONTAINMENT SYSTEMS

8-14.1 General Design Considerations

Provide a spill containment system for all aboveground tanks to prevent spilled 

petroleum from leaving the property. Individual tanks larger than 10,000 barrels (1600 

m3

) in capacity should be enclosed in an individual diked enclosure. Groups of tanks, 

with no tank larger than 10,000 barrels (1600 m3

) and not exceeding 15,000 barrels

(2400 m3) in aggregate capacity, may be enclosed in a single diked enclosure. 

Subdivide each diked area containing two or more tanks by intermediate curbs to 

prevent spills from endangering adjacent tanks within the diked area. When subdividing 

is required, use intermediate curbs not less than 18 inches (450 mm) in height. 

Designer can take advantage of the exception granted for protected tanks by NFPA 30

or NFPA 30A if the provisions of that document are met and local, state, and federal

regulations permit. Refer to DoD Standard Design AW 78-24-27. Use the following 

criteria for tank spill containment systems:

a) The preferred method of containment is by diked enclosure 

(impounding spilled fuel around the tank by means of a dikes) to 

prevent the accidental discharge of petroleum.

b) As an alternative to diked enclosures, use a remote impoundment spill 

collection system consisting of a series of drains leading from storage 

tank areas to a remote containment or impoundment designed to 

prevent the accidental discharge of petroleum. This is not the 
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preferred method and requires approval of Service Headquarters. 

Generally, this system is used for tanks on a hillside.

c) Slope the area within the containment at no less than 1 percent to 

carry drainage away from the tank to a sump located at the low point of 

the enclosure.

d) Construct the drain line from the sump of petroleum-resistant, fireresistant, impervious material. Do not use clay, concrete, fiberglass or 

plastic piping materials.

e) Control drainage from the sump to the outside of the enclosure by a 

lockable knife gate valve with indicator post located outside of the 

enclosure in an area that will be safely accessible during a fire.

f) Do not allow fuel to run off or escape from the containment area under 

any circumstances. Provide means for disposing or for treating 

contaminated water from the containment to meet the most stringent of 

applicable federal, state, or local requirements.

8-14.2 Spill Containment System Capacity

8-14.2.1 Diked Enclosures 

Design diked enclosures in accordance with the most stringent of NFPA 30, 40 CFR 

Part 112, and other federal, state and local regulations. Additionally, ensure that the 

capacity of the diked enclosure is, at a minimum, greater than the largest tank volume 

located within the diked enclosure, plus sufficient freeboard equal to the greater of a 24-

hour, 25-year storm or one foot (0.3 m) over the entire area of drainage. In the event of 

a fire, the diked enclosure must be able to contain the flow of water from firefighting 

activities for 20 minutes. In appropriate environmental climates, consider snow and ice 

accumulation as well. Limit dike heights to 6 feet (1.8 m) or less.

8-14.2.2 Remote Impoundments

If approved by Service Headquarters, design remote impoundments in accordance with 

the most stringent of NFPA 30, 40 CFR Part 112, and other federal, state and local 

regulations. Additionally, ensure the capacity of the remote impoundment is, at a 

minimum, greater than the largest tank volume located within the area of drainage, plus 

sufficient freeboard equal to the greater of a 24-hour, 25-year storm or one foot (0.3 m)

over the entire area of drainage. When sizing the remote impoundment consider the 

total drainage area from all tanks that are included within the spill collection system. In 

the event of a fire, the drainage system and impoundment must be able to contain the 

flow of water from firefighting activities for 20 minutes on neighboring storage tanks 

sharing the same spill collection system. In appropriate environmental climates, 

consider snow and ice accumulation as well.

8-14.3 Remote Containment/Impoundment Spill Collection Systems

Construct the remote impoundment as generally described for diked enclosures and in 

accordance with UFC 1-200-01 and UFC 3-600-01.
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8-14.4 Diked Enclosure – Earthen Dike Type

Construct earthen dikes of earthen materials with fuel impermeable liner cover. Where 

space is a premium, construct dikes of vertical concrete walls. For earthen dikes, make

the minimum distance from the toe of the dike to the tank foundation 5 feet (1.5 m) and 

provide a flat surface on the top of the dike at least 3 feet (0.9 m) wide. Do not make 

earthen dike slopes steeper than 1 vertical to 1-1/2 horizontal. Cover the sides and top 

of the earthen dike and the floor around the tank with one of the following materials (see 

Facility Plate 019):

a) A fuel impermeable liner. If liner is exposed, the exposed areas must 

be resistant to the effects of direct sunlight and to wind uplift. Provide 

sandbags in accordance with the appropriate UFGS to assure the liner 

is resistant to wind uplift. Follow the liner manufacturer’s 

recommendations for protecting the liner by the use of geotextile cover 

or other recommended means. Provide a concrete maintenance pad

for personnel access to the tank and for work areas around tank 

manholes and valves.

b) Do not use Bentonite or a Bentonite composite material in the 

construction of dikes or basins.

c) Do not use asphalt.

8-14.5 Diked Enclosure – Reinforced Concrete Dike Type

Design reinforced concrete (prefabricated or cast-in-place) dikes and their foundations 

to resist and contain the full hydrostatic load when filled to capacity. Consider the use 

of reinforced concrete blocks with or without exterior earth mounding. Use vertical 

reinforced concrete dikes where space is a premium. Seal all concrete surfaces with a 

flexible, UV-resistant, fuel-resistant coating if required by local or State regulations. Use 

a fuel impermeable liner as described above for the dike floor.

8-14.6 Diked Enclosure – Combination Dike Type

A vertical concrete wall backed by an external earthen berm may be used. Design the 

combined earthen and concrete unit and its foundation to resist and contain the full 

hydrostatic load when filled to capacity. Use a fuel impermeable liner as described 

above for the dike floor. 

8-14.7 Stormwater Collection Systems

Design a stormwater collection system to contain, transport, treat, and discharge any 

stormwater that collects in the tank enclosure. Refer to Chapter 2 of this UFC. Review 

state and local regulations for design requirements and permitting of stormwater 

treatment systems.

8-14.8 Dike Access

Provide concrete, steel, or aluminum steps with pipe handrails for passage across a 

dike. Steps and handrails must comply with 29 CFR Part 1910.36. Include a 

removable section of the handrail to provide access to the flat top of earthen dikes. If 

steel steps are used, they should be hot-dipped galvanized after fabrication. Provide 
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enough access locations for safe emergency egress and for normal operation. This will 

normally include steps over the dikes separating adjacent tanks, as well as on one wall 

without an adjacent tank. Locate steps at the most accessible points, preferably on the 

same side as the access stairs to a tank roof. For tanks over 10,000 barrels (1600 m3

) 

and larger, consider providing earth-filled ramps to permit vehicle access into the dike

when approved by Service Headquarters. If there is sufficient need to provide vehicle 

access into diked areas, provide a concrete paved road and/or earth-filled ramp for

vehicle travel-ways. A removable steel bulkhead section may be a cost-effective 

method to provide access for dikes with vertical reinforced concrete walls. Where the 

vehicle access road crosses the dike, provide a security gate and prominent sign 

indicating that access is limited to a 1-ton pick-up truck that is compliant with NFPA 70

Class I, Group D, Division 2 criteria.

8-15 MISCELLANEOUS USE TANKS

This paragraph provides design guidance for small miscellaneous use tanks. These 

tanks are typically less than 550 gallons (2100 L) in capacity. Check state and local 

regulations before beginning design. If a miscellaneous use tank has a capacity greater 

than 12,000 gallons (45 800 L), follow the requirements of Table 8-1. Otherwise, use 

the standards described below.

8-15.1 Installation

Install the tank in conformance with the requirements of NFPA 30. The exception used 

for the deletion of dike containment is acceptable if all of the criteria associated with that 

exception are met. Provide containment for all tanks, regardless of size, except small 

residential heating oil tanks, by complying with Paragraph 8.14 of this UFC or by using 

properly installed aboveground concrete-encased tanks in accordance with Paragraph 

8.7 of this UFC.

8-15.2 Heating Oil Tanks

Comply with NFPA 31.

8-15.3 Emergency Generator Fuel Tanks

Comply with NFPA 31, NFPA 37, and NFPA 110.

8-15.4 Fire Pump Fuel Tanks

Comply with NFPA 20, NFPA 30, and NFPA 31.

8-15.5 Waste Oil Tanks

Check local and state environmental regulations for any additional requirements for 

storage of waste oil.

8-15.6 Containment

As discussed previously in this chapter, provide containment, under and around all 

aboveground tanks except home heating oil tanks.

8-15.7 Underground Tanks

Ensure all underground tanks are double-walled and have overfill protection, as 

described previously in this chapter.
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8-16 SHIPBOARD OFF-LOAD FUEL STORAGE TANKS

8-16.1 Function

In addition to regular storage, consider a storage tank for fuel removed from ships that 

may be off-specification or otherwise not satisfactory for its intended use. This fuel may 

be downgraded to heating oil or diesel fuel marine.

8-16.2 General Design Considerations

Determine the volume requirements of the contaminated fuel storage tank by an activity 

survey. Provide bottom-loading facilities for tank truck loading and off-loading of 

contaminated fuel.

8-16.3 Locations

Locate the contaminated fuel storage tank(s) in or near the facility tank farm. Clearly 

mark the tank(s) as to the type or grade of fuel.

8-17 JET ENGINE TEST CELL FUEL STORAGE TANKS

Design jet engine test cell fuel storage and issue systems to the same standards as 

operating storage tank fuel systems (e.g., high level alarms, gauging, shut-offs, etc.). 

Normally, tanks are refilled using station aircraft refueling trucks through aircraft singlepoint refueling adaptors.

8-18 FUELS AUTOMATED SYSTEM

The Defense Logistics Agency's Business System Modernization {BSM Enterprise 

Resource Programs (ERP) - Fuels section) is an Automated Information System (AIS) 

designed to support the DESC and the Military Services in performing their 

responsibilities in fuel management and distribution. FAS is a multi-functional AIS 

which provides for point of sale data collection, inventory control, finance and 

accounting, procurement, and facilities management. BSM-ERP is composed of an 

integrated set of commercial off the shelf (COTS) software applications, based around 

an oracle relational database management system (RDBMS), which is hosted on 

commercially available computer hardware. The system will provide interfaces to 

existing logistics/financial AIS's or to be used only when directed by DLA/DESC.
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Table 8-1. Appurtenances

Item Appurtenance V-A H-A H-U F-A P-A V-U

Manhole

a A 30-inch (750 mm) diameter manhole, a minimum 

of one manhole for tanks between 1,000 gallons 

(4000 L) and 5,000 gallons (19 000 L) capacity, 

and a minimum of two manholes (both are to be at 

least 36 inches (900 mm), for tanks larger than 

5,000 gallons (19 000 L) capacity.

    

b A dedicated manhole, other than required above, 

as the primary point for piping penetrations into a 

tank (may be as small as 22 inches (559 mm)).



c A manhole located above the internal floating pan’s 

high position to aid in venting the tank during 

cleaning and to provide access to the floating pan’s 

elastomeric wiper seals as required by DoD 

Standard AW 78-24-27.



d Containment sumps and extension manhole. 

e Roof manholes in accordance with API Std 650. A 

minimum of four 24-inch (600 mm) square 

inspection hatches on fixed roof tanks with floating 

pans and two hatches on all other tanks. Locate 

the roof manholes near the perimeter of the roof at

opposite ends of a diameter and approximately 90 

degrees from the shell manholes.



f Shell manholes in accordance with API Std 650. 

Two 36-inch (900 mm) shell manholes 180 

degrees from each other. Align shell manholes 

parallel with prevailing wind direction. Hingemounted shell manhole covers.



g A bolted cover in the roof for installation and 

removal of the internal floating pan as required by 

the tank supplier based on the pan manufacturer.



Ladder/Stairs

h Internal ladders (in accordance with OSHA criteria) 

for tanks of 5,000 gallons (19 000 L) or larger.

     

i An external ladder and platform with safety railing 

for gauging and sampling in accordance with 29 

CFR Part 1910.23 (if height justifies it).

  

j Ladders, railings, toeboards, a spiral stairway, top 

platform, and handrail in accordance with API Std 

650 and OSHA requirements. Provide stairways to 

access high level shut-off and alarms. Provide 

serrated treads and non-slip coatings on stairs and 

platforms.


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Item Appurtenance V-A H-A H-U F-A P-A V-U

Level Alarms

k An individual automatic level alarm system, 

independent of the gauging device or system for 

each tank. Include high, high-high, low and lowlow level alarms. On aboveground tanks: provide 

a manual tester for all alarm sensors to ensure 

system operability without a full tank; locate level 

alarm equipment for ready access from ground 

level or stairway platforms. On aboveground 

vertical tanks, in general conformance with API RP 

2350, set high-level at 21 minutes before overflow 

level (not to exceed 95 percent) and high-high at

seven minutes before overflow level (not to exceed 

98 percent); on tanks with floating pans locate the 

low level six minutes above the low level of the 

floating pan (no less than 5 percent) and locate the 

low-low level alarm one minute (no less than 2 

percent) above the low level of the floating pan. 

For underground tanks, high and high-high will be 

90 and 95 percent, respectively (although this may 

have to be adjusted downwards for horizontal 

tanks). Provide both audible and visible alarms. 

On all tanks without floating pans, set low level 

alarm such that air is not allowed into the system. 

In determining the low level, consider the time it 

would take for the pump or system to shut down. 

Review facility size and operating method to 

determine the most desirable location for audible 

and visible alarms, this will usually be in the tank 

farm and in the operations building. Connect to 

stop issue pump on low level alarm and receipt 

pump (if in facility) on high-high level alarm. Install 

alarms on winter sun side of the tank. Comply with 

most stringent of federal, state, or local regulations. 

For vertical aboveground tanks, see Facility Plates 

014 and 015.



* 



* 



* 

  

*NOTE: State and local regulations may be more restrictive. Because underground and aboveground 

horizontal tanks will fill extremely fast in the last 5 percent, values of high level alarm positions should 

be chosen based on filling rate, tank size, and time needed to respond to the alarm condition. Adjust 

values as well for extremely large vertical tanks with small receipt rates and extremely small vertical 

tanks with high receipt rates.
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Item Appurtenance V-A H-A H-U F-A P-A V-U

Vents

l Open atmospheric vents with weather hoods and 

bird screens for tanks to be used for products with 

true vapor pressure of 0.75 psia (5 kPa) or less. 

For higher vapor pressure, or if a vapor recovery 

system is used, provide pressure/vacuum vents in 

lieu of open vents. Consider using 

pressure/vacuum vents if product quality is at risk 

by blowing sand, dust, or snow. Comply with 

NFPA 30, host nation requirements, Chapter 2 of 

this UFC, API Std 650, API Std 2000, 29 CFR Part 

1910.106, and DoD Standard Design AW 78-24-

27, where applicable. Do not use flame arrestors.

     

m Emergency relief venting with capacity in 

accordance with NFPA 30 and UL 142, as 

applicable. For vertical aboveground tanks, a 

weakened roof-to-shell seam, as specified in API 

Std 650, may be used to fulfill emergency relief 

requirements.

    

Gauge/Gauge Hatch/Stilling Wells

n A liquid level gauge calibrated in 1/16-inch (2 mm) 

graduations mounted at 60 inches (1500 mm)

above the walking surface.

     

o Automatic Tank Gauging (ATG) for all tanks with 

fuel managed through the Defense Logistics 

Agency's Business Modernization {BSM Enterprise 

Resource Programs (ERP) - Fuels section}, that 

complies with API MPMS 3. Key features include: 

measures fluid level to

±0.05 inch (1 mm); measures standard volume

±0.1 percent; measures average product

temperature ±1 F (0.5 C); measures product 

density ±1 percent; detects water in the tank sump 

to a level equal to or slightly above the water drawoff pipe; converts volume to API standard 

conditions; local tank readout; provides backup 

alarms for high, high-high, low, and low-low level 

conditions; American Standard Code for 

Information Interchange (ASCII) interface. 

     

p A 4-inch (100 mm) gauge hatch with drop tube to 

within 3 inches (75 mm) of the bottom of the tank.* 

A second 4-inch (100 mm) opening without a drop 

tube or gauge hatch.

  

* = Lowest point in the tank not the sump.

q One 8-inch (200 mm) flange nozzle for ATG 

(planned or future) near the edge of the roof for 

ready access from the stairway platform.

 
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Item Appurtenance V-A H-A H-U F-A P-A V-U

r One 8-inch (200 mm) gauge hatch for water bottom

sampling, as close to the tank center as possible. 

See DoD Standard Design AW 78-24-27.

 

s One 8-inch (200 mm) gauge hatch (planned or 

future) with aluminum, slotted stilling well extended 

to within 3 inches (75 mm) of the bottom of the 

tank* for gauging and sampling. A datum plate to 

establish a gauging zero point.

 

Piping Connection

t Inlet fill connection. See Facility Plates 016, 017, 

and 018, as applicable. For H-A tanks, Facility 

Plate 017 applies to single wall tanks only. 

  

u Main suction and low suction. See DoD Standard 

Design AW 78-24-27.



v Inlet fill pipe with horizontal exit perpendicular to a 

tank radial. Discharge is approximately 4 inches 

(100 mm) above tank floor and enlarged to reduce 

fuel velocity. An inverted trap is placed in the line 

to serve as a liquid lock to prevent entry of fire or 

an explosion from outside the fill pipe.



Overfill Protection

w Overfill protection with a hydraulically operated 

diaphragm control valve. Tanks connected to 

commercial pipelines or marine offload systems 

with restrictions on shut-off may require diversion 

to additional tankage. On vertical tanks, valve 

typically closes midway between high and highhigh levels, but ensure valve closes no later than 

on high-high level. For underground tanks, (per

NFPA 30) and in aboveground horizontal tanks,

automatically shut off the flow into the tank when 

the tank is no more than 95 percent full. Comply 

with most stringent of federal, state, or local 

regulations. For Navy, Air Force, and Army 

systems, include a solenoid on the control valve to 

close the valve as a backup. Use API RP 2350 to 

establish the proper overfill level setting. On 

gravity drop fills, replace valve with an integral high 

level shut-off valve in the drop tube. Prior to 

designing automatic valve closure features, 

conduct a surge analysis on pressure filled 

systems. See Plates 017 and 018. 

* If pressure-filled.

  

* 

  

x A lockable, welded steel overfill protection box (15 

gallon (60L) minimum) and a manual drain valve to 

return spills to the inner tank (omit the drain feature 

on aviation turbine fuel tanks).

 
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Item Appurtenance V-A H-A H-U F-A P-A V-U

Water Drawoff

y A 2-inch (50 mm) double block and bleed, plug 

valve with internal poppet at the low end of the 

tank, unless tank contains aviation turbine fuels 

with icing inhibitors. In those cases, the water 

drawoff valve may be a ball valve.



z Water drawoff connections. See DoD Standard 

Design AW 78-24-27.



aa A 1-inch (25 mm) connection from the low end of 

the tank to approximately 3.5 feet (1.1 m) above 

the ground and equipped with a positive 

displacement-type, hand-operated pump for water 

drawoff. For Air Force projects, use electrical 

pumps only.



bb A water removal suction tube at low end of tank 

with connection for water removal by truck. 

Consider installing a fixed, hand-operated pump as 

an alternative.

 

cc A central sump pump. 

Ball Joints

dd Ball joints on pipes to relieve strain caused by tank 

settling or seismic activity. Ensure that contract 

specifications do not allow piping connections to be 

made until after the tank has been completely 

tested and allowed to settle. As an alternative, 

settlement calculations can be made and piping 

flexibility can be designed to account for settling. 

In this case, pipe can be connected prior to testing.

* May be required on tanks 25,000 gallons (94 600 

L) and larger.

 

* 

Cable Supports

ee On the fixed roof of all tanks, provide two scaffold 

cable supports in accordance with API Std 650. 

Locate the supports near the center of the tank so 

that supported cables will have maximum range 

and flexibility of operation with minimum 

interference with other tank fittings.



Striker Plates

ff Striker plates under all openings used for manual 

gauging in steel tanks and all openings in 

fiberglass tanks.

     

Monitoring Port

gg A 2-inch (50 mm) monitoring port including a tube 

which provides a means to detect product leakage 

from the primary tank into the secondary tank.

 

V-A = Vertical Aboveground Storage Tank H-A = Horizontal Aboveground Storage Tank

H-U = Horizontal Underground Storage Tank F-A = Fire-Resistant Aboveground Storage Tank

P-A = Protected Aboveground Storage Tank V-U = Vertical Underground Storage Tank
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CHAPTER 9 - PIPING SYSTEMS

9-1 INTRODUCTION

This chapter provides guidance for the design of new piping portions of fueling systems, 

as discussed in other chapters of this UFC. The criteria provided is intended to be 

general in scope except where specific criteria is necessary for given situations. 

9-2 GENERAL REQUIREMENTS

Chapter 2, General Design Information, contains important information on fueling 

facilities. Do not start design of any fueling system without first becoming completely 

familiar with Chapter 2 of this UFC.

9-2.1 Design Requirements

Ensure that piping design, materials, fabrication, assembly, erection, inspection, and 

pressure tests for fuel piping systems are in accordance with ANSI/ASME B31.3 . See 

Chapter 6 of this UFC for design requirements for interterminal and installation 

pipelines. Follow appropriate guide specifications for piping design and materials 

selection. Use the following design criteria for piping systems:

a) Unless otherwise specified by Service Headquarters, provide 

underground piping systems in and around areas subject to aircraft 

ground movements. If approved by Service Headquarters, install 

piping in concrete trenches. When trenches are employed, comply 

with NFPA 415. The use of common trenches for more than one utility 

is prohibited. Fueling equipment may be aboveground where it does

not interfere with aircraft or service vehicle movements. Design all 

clearances in accordance with UFC 3-260-02 and DoD Standard 

Design AW 78-24-28. 

b) In other cases, aboveground piping is preferred where it is not 

aesthetically objectionable or not exposed to accidental damage, 

vandalism, blast damage, or sabotage.

c) The preferred method of routing aboveground piping out of a diked

area is over the top of the dike. However, avoid creating an inverted 

“U” on the suction side of a pump to avoid an air trap. Provide high 

point vents and low point drains as required, refer to Facility Plate 019. 

d) Hydrostatically test new piping systems in accordance with 

ANSI/ASME B31.3. During testing, disconnect system components 

such as storage tanks or equipment which were not designed for the 

piping test pressure or protect them against damage by over-pressure. 

Hydrostatically test systems to 1.5 times the maximum allowable 

design pressure of the ANSI/ASME B16.5 piping system flanges at 100

degrees F (38 degrees C), see Table 9-1. Test hydrant and direct 

aircraft fueling systems and installation fuel pipelines with fuel that will 

be used in the pipeline or, at a minimum, a fuel with the same 
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minimum specification flashpoint as the fuel that will be used when the 

piping is in service. The temperature of the fuel, and the ambient 

temperature, shall be at least 20 degrees F (11 degrees C) below its 

flashpoint during the test.

e) Testing with water requires Service Headquarters approval. When 

water is authorized for hydrostatic testing of fuel piping, ensure that all 

water is removed from the piping by either pigging the piping, air drying 

the line, or by vacuum extraction.

f) Lay out piping between piers and storage tanks, cross-country 

pipelines, and between bulk storage and operating tanks to 

accommodate pigging operations. Use long radius elbows, full port 

valves, barred tees, and provisions for the connection of temporary 

launchers and receivers. Refer to UFC 3-260-01 for design guidance. 

Give special consideration to smart pigging for single wall pipelines.

g) When laying out piping for single wall aircraft hydrant systems, 

consider smart pigging/pigging in the design. For systems with 

required piping slopes and high and low level drains, provide long 

radius turns, and provide spool pieces for temporary pig launchers and 

receivers. Ensure valves are accessible for removal and replacement 

with spool pieces. Where it is more economical or practical to lay 

hydrant piping flat (slope less than 0.2 percent), provide the capability 

to rapidly clean the lines with a pig or to launch a smart pig. This 

includes providing long radius turns, full port valves, barred tees, and 

pig launchers and receivers.

h) Provide thermal relief devices on all installed double block and bleed 

valves and other valves within the piping system. Provide drain out 

with non-freeze valves at all low points of pipelines.

i) Refer to Corps UFC 3-130 series for construction of aboveground and 

underground piping in arctic and subarctic conditions.

9-2.1.1 Hydraulic Design

In general, provide a hydraulic design with a velocity of 7 to 12 feet per second (2.1 to 

3.7 m/s) on pump discharge and 3 to 5 feet per second (0.9 to 1.5 m/s) on pump suction 

at full flow. If project-specific conditions make it advisable to exceed these values, 

consult the appropriate Service Headquarters. Consult with appropriate Service 

Headquarters for outlet pressure requirements. Design suction piping to ensure that the 

net positive suction head required by the pumps is available under all conditions of 

operation. Consider the following factors in selecting pipe sizes:

a) Operating requirements of the facility to be served.

b) Capital cost of the pipe.
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c) Capital cost of pumping stations and attendant facilities.

d) Operating cost of the system.

e) Harmful effects of excessive velocity of flow including hydraulic shock 

and static generation.

f) Fatigue failure caused by cyclic loading.

9-2.2 Piping Arrangement

Wherever possible, arrange piping in parallel groups to facilitate multiple use of 

supports, to minimize the amount of trenching for underground piping, and to minimize 

the number of steps or stiles needed across pipe runs. For underground applications, 

consider constructability when determining amount of spacing between pipes. Use the 

following criteria:

a) Provide looped piping systems whenever practical. Loops add to the 

flexibility and reliability of the system, contribute to product cleanliness 

by making circulation possible, and can be used to reduce the 

magnitude of hydraulic shock. Sectionalize loops by double block and 

bleed valves to provide verifiable isolation and to facilitate pressure 

testing.

b) Between mains, install cross connections for flexibility of operation and 

as an auxiliary means of continuous operation in emergency situations. 

In addition, permit the use of line blinds where space limitations 

preclude the use of removable pipe sections or fittings. Provide a 

separate piping system for each grade of fuel to be handled. Do not 

provide cross connections between grades.

c) For short runs, provide a line slope of at least 0.2 percent. For long 

runs, make line slope sufficient to establish positive drainage by 

gravity, but without excessive bury depth. Make gradients uniform 

between high and low points. Traps are undesirable because they 

provide a place for water and sediment to accumulate. Install drains at 

low points to allow removal of any water from condensation. These 

low point drains also provide the capability to remove fuel for line 

maintenance. If slope is not possible, design the system to 

accommodate pigging by providing flange connections for pig 

launchers/receivers, long curvature fittings, barred tees, and full port 

valves. Install high point vents to remove trapped air. Low point drains 

are not required on interterminal pipelines. 

d) As a general rule of thumb, provide spacing between piping that will 

allow a minimum clearance of 3 inches (75 mm) between adjacent 

flanges. In certain situations, such as in a piping trench or other 

restrictive location, it may be necessary to reduce the spacing. A 
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minimum of 12 inches (300 mm) or one pipe diameter, whichever is 

greater, should still be maintained between pipe walls. 

9-2.3 Surge Analysis

Conduct a complete surge analysis of system operation using a computer simulation 

program for all systems with quick closing valves and for aircraft hydrant and direct 

fueling systems with more than two outlets. Give full consideration to the causes and 

effects of hydraulic shock. This is especially important in closed fueling systems such 

as aircraft fueling systems where the receiving tanks or dispensing equipment may be 

damaged by shock pressure. Reduce the possibility of shock by limiting flow velocity 

and avoiding the use of quick opening/closing valves except where required for system 

operation such as hydrant pit valves. Do not reduce flow velocities below minimum 

velocity indicated in the paragraph titled “Hydraulic Design” in this chapter of the UFC. 

Every reasonable effort must be made to control hydraulic surge or shock within 

acceptable limits by the design of the piping system rather than by the use of surge 

suppressors. Surge suppressors are strictly a last resort solution and require the 

approval of Service Headquarters prior to designing into a system. For all aircraft direct 

fueling/hydrant system designs, the loop backpressure control valve is critical in 

preventing excessive hydraulic shock. Use the following design criteria and Table 9-1

for piping design pressures:

a) For all complex piping systems (main header, several laterals, mobile 

equipment), employ computer modeling techniques to determine if 

surge suppression is required. Conduct a run at steady state flow 

conditions to establish system flow rates for the scenario being 

modeled. After that, conduct a transient surge analysis imposing 

worst-case operating conditions on the system. For hydrant systems

incorporating the use of a back pressure control valve, simulate this 

valve as an active modulating valve. If acceptable peak pressures are 

exceeded, discuss the results with the Service Headquarters fuels 

engineer to review parameters used and consider alternatives. If this 

consultation produces no workable solution, perform a second surge

analysis to model the use of surge suppressors in the system. This 

analysis must indicate that damaging peak pressures are not 

exceeded. Do not use manual surge calculations, except as found 

under (c) below, because they do not account for dampening effects of 

the system and yield overly conservative results.

b) Most systems designed in accordance with this manual will have ANSI 

Class 150 flanges and the maximum allowable operating pressures 

seen in Table 9-1. Design the system such that the total pressure 

including surge, pump shutoff pressure, thermal fuel expansion effects, 

and static pressure in any part of the system never exceeds the

maximum allowable operating pressure. Other equipment items such 

as tank trucks, aircraft fuel tanks, or shipboard fuel tanks which may be

damaged by shock pressures may require lower maximum surge
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pressure. Assume a near instantaneous shut-off by the aircraft in the 

design of aircraft hydrant systems. 

c) Do not use manual calculations instead of computer modeling when 

system surge pressures are crucial and the piping system is complex. 

However, for simple piping systems that operate under 80 psi (550 

kPa) the manual calculations contained in Appendix B can be used to 

ascertain if surge will be a problem.

Table 9-1. Allowable Pressure Table – ANSI Class 150 Flanged Joints

ASTM A 105 ASTM A 182 Gr. F304 ASTM A 182 Gr. F304L

Maximum Allowable 

Design Pressure 285 psig (1970 kPa) 275 psig (1900 kPa) 230 psig (1590 kPa)

Maximum 

Hydrostatic Test 

Pressure

450 psig (3100 kPa) 425 psig (2930 kPa) 350 psig (2400 kPa)

Minimum 

Hydrostatic Test 

Pressure

425 psig (2930 kPa) 400 psig (2760 kPa) 325 psig (2240 kPa)

Maximum Allowable 

Operating Pressure 285 psig (1970 kPa) 275 psig (1900 kPa) 230 psig (1590 kPa)

Maximum Allowable 

Surge Pressure 380 psig (2620 kPa) 366 psig (2525 kPa) 306 psig (2100 kPa)

1. All pressure values are taken from ANSI/ASME B16.5-1996, ANSI/ASME 

B16.47-1996 and ANSI/ASME B31.3-1999 at 100 degrees F (38 degrees C). 

2. Values are presented for information only. Confirm actual values with 

ANSI/ASME B16.5, latest edition, based on actual temperatures, bolting and 

gasket materials, etc.

3. For other materials, see ANSI/ASME B16.5 and B31.3. 

4. For lower hydrostatic test pressures, the maximum allowable operating

pressure will be lower than indicated. See ANSI/ASME B31.3. 

9-3 ABOVEGROUND PIPING

Support aboveground piping so that the bottom of the pipe is a minimum of 18 inches 

(450 mm) above the ground surface or higher if required to service valves and 

equipment. In areas subject to flooding, greater clearance may be desirable. At 

intersections with roadways, allow enough clearance for the passage of tank trucks, 

cranes, and similar heavy vehicles. In areas subject to seismic activity, provide the 

piping configuration and support in accordance with the seismic design criteria in UFC 

3-310-04. Refer to UFC 3-130 series for considerations in extremely cold climate. 

Wherever possible, arrange piping in parallel groups to facilitate multiple uses of 

supports, to minimize the amount of trenching for underground piping, and to minimize 
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the number of pipe stiles needed. Consider constructability and maintenance in spacing 

of piping. As a general rule of thumb, provide spacing between piping that will allow a 

minimum clearance of 3 inches (75 mm) between adjacent flanges. In certain 

situations, such as in a piping trench or other restrictive location, it may be necessary to 

reduce the spacing. A minimum of 12 inches (300 mm) or one pipe diameter, 

whichever is greater, should still be maintained between pipe walls.

9-3.1 Identification

Identify piping in accordance with Chapter 2 of this UFC. In addition, mark fuel lines at 

head of fueling pier near valves, and mark valve “open” and “close" positions.

9-3.2 Pipe Supports

Rest piping on supports, both insulated and uninsulated, on a steel shoe welded to the 

bottom of the pipe. Leave the shoe free to move on the support. Construct the portion 

of pipe supports in contact with the ground with concrete. Facility Plate 020 shows the 

design of typical “slide/guide” pipe supports. Ensure that support material is the same 

as the pipe material. Other support configurations are acceptable provided the support 

does not contain rollers, does not allow movement of the pipe on a metal surface, and 

does not include hangars. Design pipe supports to meet the applicable requirements of 

ANSI/ASME B31.3 or ANSI/ASME B31.4.

9-3.3 Arrangement

Arrange pipes to provide for expansion and contraction caused by changes in ambient

temperature. Where possible, accommodate expansion and contraction by changes in 

direction in piping runs, offsets, loops, or bends. Where expansion loops or off-sets are 

not possible, use flexible ball joint offsets. Provide sliding pipe supports or other 

method of maintaining alignment on each side of the expansion joint. Do not use 

expansion devices which employ packings, slip joints, friction fits, or other non-fire 

resistant arrangements. Use ball-type offset joints to accommodate possible settlement 

of heavy structures such as storage tanks, if piping design cannot provide enough 

flexibility. Design expansion bends, loops, and offsets within stress limitations in 

accordance with ANSI/ASME B31.3 and ANSI/ASME B31.4. Thermal expansion of 

pipes should also be calculated based on the pipe being empty to include 

considerations for when the pipe is being installed or drained.

9-3.4 Anchors

Anchor aboveground piping at key points so expansion will occur in the desired 

direction. Anchors and guides may also be required to control movement in long runs of 

straight pipe or near a connection to fixed equipment such as a pump or filter. See 

Facility Plate 021. Space anchors to provide maximum amount of straight runs of piping 

from expansion points to the anchors. In general, place anchors at all points of the 

system where only minimum piping movement can be tolerated, such as at branch 

connections and equipment connections. Key locations are pump houses or other 

buildings, manifolds, at changes of direction if not used as an expansion joint, at points 

where the pipe size is drastically reduced related to adjacent piping, and at all terminal 

points. Limit the use of anchors to the situations described above. Where an anchor is 
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welded directly to a pipe, ensure that the anchor material is compatible with the pipe 

material.

9-3.5 Thermal Relief Valves

The coefficient of expansion of liquid petroleum in the range of 35 degrees to 60 

degrees API (0.8498 to 0.7389) at 60 degrees F (16 degrees C) is 0.0005 gallon per

gallon per degree F (0.0009 L per L per degree C). The total volume generated in most 

cases is very small, but the pressure increase resulting from this expansion can equate 

to as much as 75 psi for every degree rise in the fuel temperature if not relieved. For 

this reason, provide any section of pipe that has the potential to be isolated by a shut-off 

valve or other means with a thermal relief valve to relieve the isolated piping section. 

Provide a thermal relief of the internal cavity of valves where pressure is trapped when 

the valve is in the closed position (double block and bleed plug valves for example). 

The thermal relief valve should match the material of the piping in which it is installed. 

Provide valves used for relief of thermal expansion of not less than 3/4-inch (20 mm) 

nominal pipe size. It should be provided with isolation ball valves, with removable 

handles, on the inlet and outlet. The set pressure of the relief valve will vary, but 

consider a set pressure of about 10 percent above the dead-head pressure of the 

pump. This should keep the valve from opening during normal fueling operations. 

Ensure the set point is within the design limitations of the piping. Do not provide

thermal relief piping with sight flow indicators.

Thermal relief valves should never discharge to grade or to a stormwater drainage 

system. Ideally, the relief valve should discharge to a header which is piped directly to 

an atmospheric source such as a storage tank or product recovery tank. Often, the 

practical alternative, is to configure the relief valves into a cascading system, where 

each relief valve bypass the shut-off valve that is isolating the piping section and 

discharges back into the main product piping. The excess volume may pass through 

two or more relief valves before finally making its way back to an atmospheric source. 

Caution must be taken to ensure that the relief valves have the capacity to handle the 

additive relief flows this type of system creates and that the total relief pressure does 

not exceed that system maximum allowable operating pressure. In a cascading system, 

consider using balanced type relief valves. Balanced type relief valves limit pressure 

buildup that is created in a cascading system, because the balanced type relief valves 

relieve at a point independent of downstream pressure. 

In some cases a small atmospheric tank may need to be placed to properly relieve a 

piping system. This may be the case if a system component has a lower maximum 

allowable pressure then the rest of the system or in a remote location where a 

cascading system will not work. Equip the tank with self-checking high level alarms and 

containment. See Facility Plates 023, 024, 025 and 026. 

9-4 UNDERGROUND PIPING

Provide underground piping which passes under public roadways or railroad tracks in 

accordance with Department of Transportation regulations 49 CFR Part 195 and API 

RP 1102. Refer to Chapter 2 of this UFC for corrosion protection and for environmental 
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protection. Before installing underground pipelines, review all federal, state, and local

regulations for double wall pipe, leak detection, and corrosion protection requirements.

9-4.1 Depth of Cover

Use the following criteria for depth of cover over buried fuel pipelines:

a) Locate top of lines at a minimum of 3 feet (0.9 m), except that less 

cover is permissible for occasional stretches where overriding 

conditions exist, such as the need to pass over a large culvert or 

beneath drainage ditches. At such locations, build sufficient slack into 

the line to allow for vertical and lateral movement due to frost heave. 

Refer to UFC 3-130 series for additional guidance. Protective 

measures, such as the installation of reinforced concrete slabs above 

the pipe, may also be required where depth is less than required under 

Paragraph (b) below.

b) Subject to Paragraph (a), provide minimum depths in accordance with 

49 CFR Part 195 and federal, state and local regulations. Under 

roadways and shoulders of roadways, provide a minimum depth of 4 

feet (1.2m).

9-4.2 Parallel and Crossing Pipes

Provide a minimum clearance of 12 inches (300 mm) between the outer wall of any 

buried POL pipe and the extremity of any underground structures including other 

underground pipe. Where pipelines cross and a minimum clearance of 12 inches (300 

mm) cannot be achieved, provide an insulating mat between the pipes and centered 

vertically and on the point of intersection. Insulating mat shall be constructed of 

neoprene or butyl rubber and shall be 36 inch (900 mm) by 36 inch (900 mm) and 1/8 

inch (3 mm) thick. Provide a test station with two test leads from each pipe. See UFC 

3-570-02N, Electrical Engineering Cathodic Protection for more information. Where 

non-government and government owned pipe cross or are in proximity of less than 150 

feet, contact owner of non-government pipe for coordination to prevent/mitigate cathodic 

protection interference. In areas where multiple utilities are routed in the same area 

(e.g., a utility corridor), make sure electrical and communication ducts/conduits are kept 

a minimum of 36 inches (900 mm) from all other underground utilities especially fuel, 

steam, and high-temperature water pipes. Refer to ANSI /IEEE C2, ANSI/ASME B31.4, 

and 49 CFR Part 195 for additional requirements. For pipes in concrete trenches, 

provide a minimum clearance of 6 inches (150 mm) between flanges and the trench wall 

and between adjacent flanges. If there are no flanges, provide a minimum clearance of 

12 inches (300 mm) or one pipe diameter (based on largest pipe), whichever is greater, 

between the pipe and the trench wall and between adjacent pipes within the concrete 

trench. 

9-4.3 Casing Sleeves

Use steel casing sleeves only for those crossings where sleeves are required by 

authorities having jurisdiction, where it is necessary to bore under the roadway or 

railroad tracks to avoid interference with traffic, or where boring is the most economical 
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construction method. When planning construction of open trench crossings, consider 

the economics of installing spare casing sleeves to eliminate excavating for future fuel 

lines. Ensure that the design isolates fuel-carrying pipes from contact with the casing 

pipes. Require a seal of the annular space at each end of the casing. Include a vent on 

the higher end of each casing. Locate crossings at a minimum depth of 36 inches (900 

mm) beneath the bottom of drainage ditches. If this depth cannot be obtained, install 

above, but not in contact with, the casing or pipe, a 6-inch (150 mm) thick reinforced 

concrete slab of adequate length and width to protect the casing or pipe from damage 

by equipment such as ditch graders and mowers. Refer to API RP 1102 for additional 

information.

9-4.4 Line Markers

Except where prohibited by national security considerations, install line markers over 

each buried line and allow for maintenance provisions in accordance with 49 CFR Part 

195.

9-4.5 Warning Tapes

Provide buried warning tape for all underground pipelines as required by the appropriate 

guide specification.

9-4.6 Double-Wall Piping

Provide double-wall piping for Ground Vehicle Fueling Facilities. For other applications, 

do not use double-wall piping unless required by state or local regulations, and 

approved by Service Headquarters. Service Headquarters approval to use doublewalled pipe must be obtained at the programming level and at the 35 percent design 

level.

9-4.7 Single-Wall Piping Leak Detection Systems

For all single-wall buried pipe not used in aircraft direct fueling systems, consider

providing a leak detection system approved by Service Headquarters. 

9-4.7.1 Leak Detection for Aircraft Direct Fueling Systems

For aircraft direct fueling systems, provide an automatic leak detection system approved 

by Service Headquarters, to test all buried portions of the piping system. Automatic 

leak detection systems measure changes in either the volume or pressure of the fuel in 

a fixed piping system, while accounting for variations in ambient temperature. The 

pressure type shall work by measuring the time rate of change of line pressure at two 

different pressures. The volume type shall work by measuring the amount of fuel 

required to maintain a constant pressure in a line, also at two different pressures. The 

system shall have sufficient sensitivity to detect leaks of at least 0.004 percent of line 

volume with a Probability of Detection = 95 percent and a Probability of False Alarm = 5

percent. All leak detection system shall be third party certified. 

9-5 UNDERWATER PIPING

To receive fuel from offshore moorings, provide one or more underwater pipelines from 

the shore facility to the mooring. Limit the design of these systems to engineers with 
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this type of experience. Coordinate offshore piping systems with NFESC-Ocean 

Construction Division.

9-5.1 Special Arrangements

At the mooring end of each pipeline, provide lengths of submarine fuel hose equal to 2.5 

times the depth at high water. At the pipe end of the hose, provide a flanged removable 

section of hose 10 feet (3 m) long. At the free end of the hose, provide a steel valve 

with a marker buoy attached to a cable or chain which has sufficient strength and 

suitable fittings for the vessel to lift the hose and valve aboard.

9-5.2 Connections

Lay out multiple fuel lines and connections so that they correspond to the layout of the 

ship’s discharge manifold.

9-5.3 Unique Considerations

In piping design, consider fuel characteristics as they may be affected by the sea water 

temperature, particularly in cold water. For diesel fuel, aviation turbine fuel, or other 

light fuels, small individual lines are preferable as follows:

a) Minimum nominal pipe size of 6 inches (150 mm).

b) For transfers of fuels exceeding 3,000 gpm (189 L/s), use 12-inch (300 

mm) to 16-inch (400 mm) diameter pipe.

c) Instead of pipes larger than 16 inches (400 mm) in diameter, consider 

using two smaller diameter pipes.

d) At an accessible upland location, as close to the water entry as 

practical, provide a double block and bleed valve and a manually 

operated check valve or bypass to allow reversal of flow when 

required.

e) Provide a dependable means of communication between the vessel in 

the offshore berth and the shore facility.

9-5.4 Corrosion Protection

Wrap, coat, and cathodically protect underwater pipelines in accordance with Chapter 2

of this UFC.

9-5.5 Depth of Burial

Provide sufficient burial depth of underwater pipelines to prevent damage by dredging of 

the waterway, by ships’ anchors, trawls, or by scouring action of the current. 

Specifically, ensure depth conforms to the requirements of 49 CFR Part 195. Where 

lines cross ship channels or anchorages, ensure the top of the pipe is at least 12 feet 

(3.7 m) below the theoretical, present or planned future bottom elevation, whichever is 

deeper. Recommended backfill in such areas is 2 feet (0.6 m) of gravel directly over the 

pipe, followed by stones weighing 50 to 60 pounds (23 kg to 27 kg) up to the bottom 

elevation.
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9-5.6 Pipe Thickness and Weight

Provide sufficient pipe wall thickness to keep stresses due to maximum operating 

pressure and other design loads within design limits. Include full consideration to extra 

stresses which may occur in laying the pipe. It is common practice to use heavier wall 

pipe for water crossings of more than 200 feet (60 m) from bank to bank at normal water 

level. This affords greater stiffness and resistance to buckling during handling of the 

assembled crossing pipe and requires less weighting material to obtain the necessary 

negative buoyancy to keep the line in place while empty or containing a light product. 

Reinforced sprayed-on concrete is an acceptable weighting material. Hydrostatically 

test assembled crossing pipe before placing, unless crossing pipe is too long for prior 

assembly in one segment. In this case, separately test each segment as described.

9-6 PIPING MATERIALS

9-6.1 Non-Aviation Systems

Use carbon steel piping material for interterminal pipelines (regardless of product) and 

for all portions of non-aviation turbine fuel systems. FRP may be used for underground 

pipe (not in concrete trenches) in ground vehicle fueling facilities. FRP is not to be used 

in aviation turbine fuel system applications. The appropriate service guide specification 

includes the necessary requirements. See Facility Plate 022.

9-6.2 Aviation Systems

New systems shall use stainless steel issue piping. Interior coated carbon steel may be 

used only with the approval of the Service Headquarters for piping downstream of the 

last issue filter/separator. Return piping shall be interior coated carbon steel. Give 

special consideration to the pressure rating of both the pipe and fittings to ensure 

adequacy to accommodate surge pressure. See Facility Plate 022 for piping material 

options.

9-7 WELDING CRITERIA

Ensure that the contract requires welding and welding inspections in accordance with 

appropriate guide specifications and/or standard design. Proper welding, done in 

accordance with the guide specifications, will prevent loose and adhered slag on the 

inside of the pipeline. Use 100 percent radiographed weld joints meeting the standards 

for severe cyclic service contained in ANSI/ASME B31.3 for piping downstream of the 

pump in hydrant systems. For all other underground steel pipes, use 100 percent 

radiographed weld joints meeting the requirements of ANSI/ASME B31.3.

9-8 PIPING CONNECTIONS

a) For steel piping systems, use weld neck forged flanges with raised 

faces having a modified spiral serrated gasket surface finish.

b) Do not use cast iron flanges.

c) Do not use grooved pipe type couplings or similar fittings in permanent 

fixed piping systems.
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d) Do not direct bury flanges, valves, mechanical couplings, threaded 

fittings, or any mechanical equipment. If they must be used in an 

underground system, enclose them in an accessible pit.

e) Use welded connections for joining steel pipe. Use flange connections 

for joining pipe to equipment. Use threaded connections only where 

unavoidable such as on differential pressure gages, pressure 

snubbers, and fuel sample points. 

f) Use carbon steel bolts, studs, and nuts with carbon steel flanges. Use 

stainless steel bolts, studs, and nuts with stainless steel flanges. 

Stainless steel bolts may be used on carbon steel flanges in corrosive 

environments. Select stainless steel bolts, studs, and nuts based on 

seizing and elongation. Coordinate both strength with force needed to 

compress selected gasket. In locations where severe corrosion 

(typically salt air) is susceptible use flange and bolt seals, filled with 

grease preservative, as required to prevent and control corrosion. 

g) In steel piping systems, use socket weld joints on 2-inch (50 mm) 

diameter nominal size and smaller pipe.

h) Make branch connections with butt welded tees except where the 

branch is at least two pipe sizes smaller than the run, in which case the 

branch connection can be made with a forged or seamless branch 

outlet fitting, which is designed in such a way that the connection can 

be radiographed. 

i) Do not use wrinkle bends or mitered bends for changes in direction.

j) Except for unions and control tubing couplings, do not use threaded 

joints in stainless steel systems. Socket-weld stainless steel drain, 

vent, and pressure relief valve lines 2-inch (50 mm) in diameter or less. 

If aboveground, flanges may be used.

k) Join glass FRP piping by bell and spigot joints sealed with adhesive, 

except use FRP flanges for connections to flanged equipment such as 

pumps or valves. Ensure that no loading can be transferred from steel 

piping to FRP piping.

l) Connect all dissimilar metals with isolation flanges.

9-9 INTERIOR PIPE COATINGS

To protect aviation fuel quality and extend the life of the piping, minimize bare carbon 

steel piping (except interterminal pipeline) which comes in contact with aviation turbine 

fuels especially downstream of initial filtration equipment. Maximize the use of internally 

coated pipe. This is not intended to allow the use of lined carbon steel piping as a 

substitute for areas requiring non-ferrous piping. Comply with other paragraphs of this 

chapter for material selection. Interior pipe coating is not required on non-aviation 
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piping except for carbon steel piping within the lower 36 inches (900 mm) of 

aboveground vertical storage tanks, and ballast lines on piers.

9-10 EXTERIOR PIPE COATINGS

a) Protect the exterior surfaces of all underground steel piping systems 

with a continuously extruded polyethylene coating system or fusion 

bonded epoxy. Coat welded joints with a system compatible with the 

pipe coating.

b) Protect the exterior surfaces of all aboveground carbon steel piping 

systems by coating in accordance with applicable service requirement. 

Exterior surface of pipe shall be prepared by abrasive blasting and 

cleaned prior to coating application.

c) Coat underwater piping with the same materials used for underground 

piping. In addition, coat underwater piping with a reinforced sprayedon concrete, or similar type material, for pipe stabilization and to 

provide negative buoyancy when the pipeline is empty.

9-11 SAMPLING FACILITIES

Provide connections for sampling fuels on each section of a fuel transfer piping system. 

Install sampling and testing connections at receiving points, tank outlets, inlet and outlet 

sides of filter/separators, all fuel dispensing points, and between isolation valves so that 

the remaining fuel in each portion of a fuel transfer pipeline can be sampled. Where 

possible, install sampling connections in vertical runs. Provide a 1/4-inch (8 mm) 

diameter sample point with a probe, ball valve, and quick disconnect with dust cap.
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CHAPTER 10 - ALTERNATE POL FACILITIES

10-1 INTRODUCTION

This chapter provides guidance for design of alternate POL facilities. The alternate 

fuels discussed are: LPG, CNG, hydrazine, and OTTO fuel. This chapter contains 

information on products which are unique. Therefore, some special considerations are 

discussed, in addition to information provided in Chapter 2, General Design Information, 

which contains important information on fueling facilities. Do not start the design of any 

fueling system without first becoming completely familiar with Chapter 2 of this UFC.

10-2 LIQUEFIED PETROLEUM GAS (LPG)

10-2.1 Uses

The uses for which LPG fuel is procured and the methods of transportation of the fuel 

are as follows:

a) LPG fuel is used for general heating, metal cutting and brazing, and in 

laboratories. LPG is procured in cylinders or for bulk storage by tank 

car or tank truck. Cylinders usually contain 100 pounds (45 kg) of gas, 

in a liquid state.

b) Fuel supply for firefighting trainers and crash and rescue training 

facilities.

c) Where economically justified, LPG facilities supplement utility-supplied 

gas systems for meeting peak loads and as a standby where 

interruption to a supply is possible.

(1) Standby LPG facilities serving large capacity equipment, such as 

boilers of 200,000 British thermal units (Btu's) per hour (58 000 

W) and above, may consist of a separate gas system to an 

alternate set of burners on the equipment.

(2) For a gas system serving multiple small appliances, provide the 

standby equipment with means for air mixing to dilute the LPG 

with the proper amount of air to match combustion 

characteristics of either natural or manufactured gas serving the 

system in place of the utility-supplied gas, or in conjunction with 

it to reduce utility peak loads.

10-2.2 General Design Considerations

LPG is odorless, colorless, non-toxic, heavier than air, and explosive. To permit easier 

leak detection, an artificial odor may be introduced when shipped from a refinery. 

Under standard atmospheric conditions, LPG is in a vapor phase, but it is liquefied 

under moderate pressure for shipping and storage. The maximum vapor pressure for 

LPG design is 215 psig (1480 kPa) at 100 degrees F (38 degrees C). All LPG 
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purchased by the military should emit a distinct odor at a concentration required by 

NFPA 58. See Facility Plates 027, 028, 029 and 030.

10-2.2.1 Fire Hazards

In the vapor phase, LPG is a hazard comparable to flammable natural or manufactured 

gas. The explosive range is 2.16 to 9.6 percent by volume of air-gas mixture.

a) Provide ventilation in accordance with NFPA 58. 

b) In the liquid phase, LPG is a highly volatile, flammable liquid. Because 

of rapid vaporization, an LPG fire is basically a gas fire. Therefore, in 

the event of a fire, provide means to automatically shut off the LPG 

supply feeding the fire.

c) Provide emergency shut-off consisting of the combination of three 

modes: manual shut-off, remote shut-off, and thermal shut-off. 

Remote shut-off normally consists of a nitrogen system with plastic 

tubing at the controlled point so that the pressure holds open the valve. 

The plastic tubing acts as a fusible link. Provide a cable release shutoff with remote shut-off for combination shut-off. Refer to UFC 4-179-

01 and API Std 2510. 

d) Provide leak detection in accordance with NFPA 59. 

e) For LPG equipment located inside buildings where there is a potential 

for loss of LPG, provide an alarm/detection system with local and 

remote alarms (audible and visual), high and low ventilation, doors with 

panic hardware, a leak detector readout with the readout outside, and 

a leak detector kit located outside.

10-2.2.2 Refrigerating Effects

At normal atmospheric pressure, the boiling point of propane is -45 degrees F (-43 

degrees C). Propane in a liquid state and open to the atmosphere will evaporate (not 

boil).

a) Provide means to address operational concerns as described in the 

following paragraph. When LPG is expanded through a regulator from 

its vapor pressure to normal service pressures, the cooling effect may 

freeze the regulator if water is present in the LPG. Freeze-up can also 

occur on equipment which accumulates water such as strainers and 

control valves. The freezing effect can also result in exterior ice 

formations which disrupts the valve operator. Freeze-ups can be 

avoided by cleaning and nitrogen-purging the system.

b) Although it is dehydrated at the refinery, provide a means to keep LPG 

dry.
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c) In flashing to vapor from the liquid phase, the refrigerating effect can 

be severe if an abrupt pressure drop occurs. Therefore, design a 

system which provides means to avoid this problem.

10-2.2.3 Design Standards

Use the following references for general design and safety standards for all LPG 

facilities. (Follow particular sections of standards applicable to types of facilities. 

Where conflicts occur, use the more stringent requirements.) Appropriate standards are 

as follows:

a) NFPA 54, NFPA 58, and NFPA 59. 

b) API Std 2510. 

c) Gas Processors Association Standard 2140. 

d) Commercial Item Description A-A-59666, Sections ICC 4BW, ICC 4E, 

and ICC 4BA.

e) UFC 4-179-01. 

f) Factory Mutual Engineering Corp. (FM), Loss Prevention Data, Liquid 

Petroleum Gas, Section 7-55. 

10-2.3 Receiving Facilities

10-2.3.1 General Design Considerations

LPG may be received by truck, rail, or water for either cylinder (bottled gas) or bulk 

systems. 

10-2.3.2 Transfer Methods

Design the facility to accommodate one of the following transfer methods:

a) No pumping or pressurizing facilities are required for small bulk 

systems utilizing truck delivery. Use pumping equipment provided on 

trucks instead of stationary pumps.

b) Provide LPG vapor piping, pumps, and compressors for off-loading 

tank cars or waterborne LPG tanks to operate, as follows:

(1) Provide compressor and piping to take suction from the vapor 

space of the storage tanks to be filled through an equalizing line 

and pressurize the tank to be off-loaded. This forces the LPG 

out through the liquid off-loading line into the storage tank.

(2) Arrange the piping so that after all liquid has been evacuated, 

the compressor suction can be reversed to pump the LPG gas 
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from the delivery tank to the storage tank through a subsurface 

dip tube.

(3) Provide connections and valving to allow bleeding of the liquid 

propane from the connection after shutting off the valve at both 

the hose end and at the off-loading piping. This is done after offloading the liquid from either a transport truck or a tank car. 

Provide a bleed attachment built into the off-loading equipment 

for this purpose.

(4) See Facility Plates 027, 028, 029 and 030 for typical installation. 

Provide liquid pumps as standbys for compressors.

c) Provide the transfer point from trucks or tank cars with a substantial 

concrete bulkhead. Anchor the piping in the bulkhead. Do not use 

pipe sleeves. Provide with the bulkhead hose or swivel-type piping 

connections. The bulkhead provides a breakaway point if the truck or 

tank car moves away without first disconnecting the hoses. Also 

provide emergency shut-off and excess flow valves. Refer to NFPA 58

and UFC 4-179-01 for additional information.

10-2.3.3 Flow Rates

Use the following flow rates:

a) Provide flow rates commensurate with the storage capacity and the 

size of pumps, compressors, and loading devices.

b) Provide flow rates that allow operators adequate time to shut down 

facilities before tanks or trucks are filled beyond maximum allowable. 

Limit flow rates from tanks by setting excess flow valves.

c) Provide off-loading lines with manually operated throttle valves so 

operators can adjust flow rates to points below shut-off settings of 

excess flow valves.

10-2.4 Storage Facilities

10-2.4.1 Types of Storage

Types of storage facilities include cylinders or bulk storage tanks. 

a) Provide cylinders or containers conforming to ASME and/or DOT 

criteria as described in guide specifications. Used tanks are not 

allowed. The number of cylinders at a facility depends on the 

maximum required flow rate and the vaporization rate per cylinder at 

the minimum operating temperatures.

b) Provide bulk storage tanks as follows:
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(1) For storage tanks up to 30,000 gallons (114 000 L) capacity, use 

horizontal steel tanks.

(2) For storage tanks above 30,000 gallons (114 000 L) capacity, 

use spherical or spheroidal steel tanks.

(3) Do not use underground tanks for LPG.

10-2.4.2 Number and Size of Bulk Tanks

Storage capacity depends on requirements, frequency of deliveries, and dependability 

of supply. Consider a multi-tank system for more dependability.

10-2.4.3 Design Requirements

Design requirements are as follows:

a) Tanks and tank appurtenances require conformance with NFPA 58

and API Std 2510. Design LPG tanks for a minimum working pressure 

of 250 psig (1700 kPa).

b) Tank spacing requires conformance with UFC 4-179-01 and FM 

criteria. See Facility Plates 029 and 030. 

c) Provide sufficient flexibility in piping connections to tanks to allow for 

differential settlement of tank and equipment.

d) Provide cathodic protection in accordance with Chapter 2 of this UFC.

e) If using compressor transfer systems, fit tanks with dip pipes a 

minimum of 3/4 inches (20 mm) diameter, and gas inlet lines from 

compressors, so that gas pumped into storage tanks from empty 

delivery vessels is bubbled through liquid LPG to prevent 

overpressuring tanks.

f) Provide float-actuated high-level alarms set at maximum permissible 

filling level of 80 percent on all tanks of 3,000 gallon (11 000 L) 

capacity and above.

g) If using installed transfer systems, provide pressure switches on tanks 

set to open at pressures 5 psig (35 kPa) below set pressures of safety 

valves to stop compressor pumps transferring LPG to tanks.

h) Ensure that tanks are ASME coded and have the ASME national 

registration number.

i) Size storage tanks for 120 percent of required storage volume. 

j) Electrically ground all storage tanks.
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10-2.4.4 Inspection, Testing, and Certifications

Inspect, test, and certify all new unfired pressure vessels prior to placing into operation. 

Do not operate the unfired pressure vessel (UPV) without a valid certificate. Perform 

the following tests on the UPV:

a) A general UPV site inspection

b) An external UPV inspection

c) An internal UPV inspection

d) A hydrostatic test (strength and tightness tests)

e) An operational test

The inspector must be registered by the National Board of Boiler and Pressure Vessel 

Inspectors (NBBI) and must possess a Certificate of Competency and a NBBI National 

Board Inspection Code (NBIC) Commission. Upon completion and passing of the 

inspections and tests, the tank will be certified. Post a current, valid certificate on or 

near the UPV under a protective coating.

10-2.5 Distribution Facilities

See Facility Plates 027, 028, 029 and 030.

10-2.5.1 General Design Considerations

The following distribution system requirements apply to the transfer of both the gas and 

liquid phases of LPG:

a) Lay all distribution piping underground when practicable.

b) Provide the required flow rates.

c) Install electrical equipment in accordance NFPA 70 and API RP 500. 

Use only equipment approved for each classified area. Ensure 

electrical design conforms to API RP 540. 

d) Ground and bond all piping, tanks, and equipment in accordance with 

API RP 2003, API Std 2510, API RP 540, and NFPA 70. 

e) Refer to Chapter 2 of this UFC for corrosion protection requirements of 

underground pipe.

10-2.5.2 Piping Materials

Provide pipe, valves, and fittings in accordance with applicable sections of API Std 

2510. Use Schedule 80 welded carbon steel. Threaded connections are only allowed 

for valves and equipment. Provide design characteristics and features for gas and 

liquid pipelines in accordance with Chapter 9 of this UFC. The minimum design 

pressure for liquid LPG piping is 350 psig (2400 kPa) as required by NFPA 58. Use 

Class 300 ANSI flanges as a minimum.
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10-2.5.3 Accessories

a) Provide totalizing-type meters, pressure gauges, thermometers, 

strainers, and surge suppressors. 

b) Ensure that meters are turbine-type with pressure and temperature 

compensation and have electronic/digital readout capability.

c) Install meters, if required, in accordance with requirements of API 

MPMS 5. 

d) Provide pressure gauges of suitable range on all tanks, on suction and 

discharge of pumps and compressors, on inlet and outlet of vaporizers 

and on downstream of throttle valves.

e) Provide thermometers on all tanks, in all transfer lines for both liquid 

and gas, and on inlet and outlet of vaporizers.

f) Provide strainers in compressor suctions, upstream of meters and 

control valves.

g) Provide surge suppressors on liquid lines, if required.

h) Provide knock-out drums or scrubbers of suitable capacities in suction 

lines of compressors to remove entrained liquid. Provide drums with 

high level, shut-down devices, automatic liquid drainers, glass gauges, 

and drains.

i) Ensure all valves are UL listed or FM approved for LPG service. At a 

minimum, use Class 300 valves.

j) Provide equipment to inject alcohol into the LPG off-loading line. 

Provide equipment capable of injecting alcohol at a rate of 1:800

alcohol to LPG by volume.

10-2.5.4 Pumps and Compressors

Design and install pumps and compressors in accordance with API Std 2510 and NFPA 

58. 

10-2.5.5 Vaporizers

Provide vaporizing equipment for distribution facilities as follows:

a) Provide vaporizers at locations where liquid temperatures are too low 

to produce sufficient vapor pressure to meet the maximum required 

flow rate.

b) Use vaporizers that are indirect fired-type utilizing steam or hot water 

as a heating medium or direct fire waterbath-type.
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c) Size vaporizers to provide at least 125 percent of expected peak load.

d) Design and install vaporizers in accordance with NFPA 58. 

e) Use waterbath vaporizers approved by Factory Mutual.

f) Space waterbath vaporizers in accordance with FM Section 7-55, 

except provide a minimum of 75 feet (23 m) between truck off-load 

stations and tank storage. Where space is limited, provide a blast wall 

at the truck off-load stations.

g) When using waterbath vaporizers, provide fire-safe fusible link shut-off 

valves in LPG supply piping at the vaporizers. Provide remote shut-off 

capability and 24-hour remote monitoring.

h) When using waterbath vaporizers, provide an automatic excess 

flow/emergency shut-off valves in LPG supply lines to vaporizers. Use 

a hydraulically operated diaphragm control valve and locate at tank 

storage.

10-2.5.6 Controls

Provide the following controls.

a) Use pumps and/or compressors that can be started and stopped by 

manual pushbutton.

b) Provide automatic limit switches as follows:

(1) Pressure switches on storage tanks set 5 psig (35 kPa) below 

relief valve settings.

(2) Liquid level switches on storage tanks set at maximum filling 

levels.

(3) Liquid level switches on knock-out drums set to shut off 

compressor at high liquid levels.

(4) High pressure switches in compressor discharges to shut off 

compressor at safe pressure levels.

c) Provide manually operated throttle valves in liquid off-loading lines to 

adjust flow rates below excess flow valve settings on delivery tanks.

d) Provide a sight flow indicator in liquid lines near throttle valves.

e) Provide automatic temperature, pressure, and limit controls on 

vaporizers in accordance with NFPA 58. 
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10-2.6 Air Mixing Facilities

10-2.6.1 Pressure Controls

Provide pressure control valves in both air and gas lines to air mixing equipment. 

Provide a low pressure alarm in both lines to shut-off air and gas in the event of low 

pressure.

10-2.6.2 Volumetric Controls

Provide volumetric controls at all distribution facilities as follows:

a) Provide displacement-type or flow-type meters in both air and gas lines 

to maintain a proportional flow of air and gas.

b) Use a venturi-type proportioner where the variation in demand flow 

rate does not exceed the limited range of the venturi proportioner. 

Where the demand flow rate varies excessively, use a venturi-type 

proportioner in conjunction with a downstream storage tank, if 

economically justified. The storage tank will permit a varying rate of 

flow to the system while being filled continually or intermittently at a 

constant rate of flow through the proportioner.

10-2.6.3 Specific Gravity Indication

Provide a specific gravity indicator and recorder with high and low-limit switches to 

sound an alarm if the variation of specific gravity of an air-gas mixture exceeds 

acceptable limits of the system. For air mixing systems using LPG with a propane 

content of 90 percent and above, the specific gravity of the air-gas mixture is a 

sufficiently accurate index of its Btu or joule (J) content, so calorimetric controls and 

indication are not required.

10-2.6.4 Calorimetric Controls

Where economically justified, provide an automatic calorimeter to indicate and record 

the Btu or J content of the air-gas mixture. Provide high- and low-limit switches to 

calorimeter to sound an alarm if the variation of Btu content exceeds acceptable limits of 

the system.

10-3 COMPRESSED NATURAL GAS (CNG)

Design CNG storage and dispensing facilities to comply with NFPA 52 and appropriate 

sections of NFPA 55. 

10-3.1 Uses

CNG is primarily used as an alternative fuel in light duty vehicles although it and its 

cryogenic counterpart liquid natural gas are gaining acceptance in heavy duty 

applications. Energy policy has mandated with certain reservations that by fiscal year 

2000 and thereafter, 75 percent of the light-duty vehicles purchased by the government 

will use alternative fuels. Therefore, there will be a significant increase in alternative 

fuel consumption.
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10-3.2 General Design Considerations

10-3.2.1 System Sizing

To size the system, determine the total daily fuel consumption of base liquid natural gas 

vehicles. Based on daily miles driven, determine the number to be refueled each day. 

The number of vehicles refueled during surges limits the capacity of most fast fill (3 to 6 

minutes) operations. Scheduling vehicles to refuel through the day will effectively 

increase system capacity. Use a computer program to size the system because manual 

calculations usually result in larger systems than needed. Refer to the Gas Technology 

Institute in the References section of this UFC for ordering information of one possible 

program. Use the latest version.

10-3.2.2 Future Requirements

Anticipate future requirements when sizing the system but normally limit the project to 

100 to 150 standard cubic feet per minute (scfm) (47 to 71 L/s). If additional capability 

will be needed in the future, plan a second system later or consider other options such 

as slow fill systems for overnight fueling. This will provide redundancy and reduce initial 

cost. Usually, surge requirements drive machine size and can be controlled by 

management actions. Additionally, boosters operating from system pressure or special 

control systems may increase surge handling capacity (e.g., 25 to 30 percent of the gas 

in a cascade system is available for fast fill operations. A booster or special control 

system can increase it to 60 percent.) The combination of these actions could delay 

installing a second system many years at most installations.

10-3.2.3 Pressures

Most vehicle conversions use 3,000 psig (21 000 kPa) storage systems while original 

equipment manufacturers use 3,600 psig (25 000 kPa) systems. The compressors 

should operate up to 5,000 psig (35 000 kPa) to refuel at either pressure.

10-3.2.4 Connections

Design the systems to be skid-mounted with compressor system, cascade storage, and 

controls. Limit field tie-ins to connecting electricity and high and low pressure gas.

10-3.2.5 Compressors

Use crosshead guide type compressors for CNG service. Although more expensive, 

the design life of these units is significantly longer. Another option is a conventional 

style compressor designed specifically for CNG service. Do not use modified air 

compressors. Choose the type compressor after comparing maintenance and reliability 

data. Test all compressors at the factory with natural gas before shipping.

10-3.2.6 Compressor Drives

Use either electric or engine-driven compressor drives. Gas engine drives are less 

expensive to operate, but maintenance costs are higher. Use a life cycle cost analysis 

to determine which compressor drive is best. Although an engine-driven compressor is 

more expensive than an electric motor, electrical upgrade costs may be reduced. It also 

may be able to operate during power outages.
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10-3.2.7 Compressor Inlet Pressure

Suction pressure is a key factor in selecting a compressor. Use high pressure gas 

mains to reduce both initial and operating costs. Avoid pressures less than 20 psig (140 

kPa). If high and low pressure lines are near each other and the pressure differential is 

at least 150 psig (1030 kPa), 250 psig (1720 kPa) is preferred, and the low pressure line 

has a continuous load, a system can be installed and powered by the differential 

pressure. Such systems are extremely effective and have low initial and operating 

costs. Where a high pressure differential exists, another option is a turbine to drive the 

compressor.

10-3.2.8 Storage

Install a cascade system using ASME vessels; either tubes or spheres. Avoid banks of 

DOT cylinders since they must be inspected every 5 years.

10-3.2.9 Controls

Use either pneumatic or electronic controls depending on local practices. Electronic 

controls are preferred in most areas because they provide more accurate compensation 

for temperature effects. Pneumatic controls are simpler, but do not fill tanks to their 

limits. Normally, this is not a problem, since base vehicles do not normally operate to 

their maximum range in one day. Since vehicle tank pressures are rated at 70 degrees 

F (21 degrees C), tanks will fill to a higher pressure when outside temperatures are 

warmer and to a lower pressure when temperatures are cooler.

10-3.2.10 Dispensers

Although more expensive, provide conventional rather than post style dispensers. To 

reduce installation costs, use dispensers with the electronics internally mounted and 

calibrated at the factory. A dispenser makes CNG refueling similar to conventional 

refueling. Depending on funds, a post style dispenser is an option.

10-3.2.11 Nozzles

Use the industry standard nozzle. It comes in three pressure ranges: 2,400 psig 

(16 500 kPa), 3,000 psig (21 000 kPa), and 3,600 psig (25 000 kPa). These nozzles

are designed so that a fill system cannot connect to a vehicle tank with a lower pressure 

rating, yet it can connect to vehicle tanks with higher ratings.

10-3.2.12 Environmental Considerations

a) The compressor unit’s receiver is usually blown-down automatically, 

releasing about 0.06 gallons (0.2 L) of oil to the base and subsequently 

the ground. Discharges from other components, such as intercoolers, 

add to the contamination. Therefore, drip gutters with drains are 

required at each corner of the base. Develop a means of collection 

and retention of these wastes. Deactivating the automatic dump 

features and manually draining is an alternative to a collection system.
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b) Provide gas recovery system as part of the compressor package to 

recover gas into an ASME recapture tank when off-loading the 

compressor.

c) At the dispenser, provide a vent 8 feet (2.4 m) to 10 feet (3 m) above 

ground level to discharge vent gas from dispenser hoses. Oversize 

the conduit from the dispenser to the cascade for a vent line to a future 

gas recovery system.

d) Locate units with care because of noise. Use landscaping to conceal 

units and attenuate the sound.

e) Natural gas engine drives, if used, may require an air emissions 

permit.

10-3.2.13 Weather

As a minimum, protect compressor units from the weather with a canopy. In colder 

climates, use a heated shelter/enclosure with sound attenuation. Some vendors have 

enclosures as normal options. Costs vary widely depending on the degree of 

protection. Enclosures may require ventilation and Class I, Division 1 classified 

electrical components. They should also be accessible by inspectors and servicing 

personnel. In lieu of a heated facility/enclosure, crankcase heaters and/or circulating 

block heaters may be suitable in moderately cold climates.

10-3.2.14 Coatings

The CNG equipment comes factory-painted. Specify special coatings where climatic 

conditions warrant. Select a color from the base color scheme. Light beige is a 

practical choice. White is a poor choice since the heat of operation discolors it. Storage 

containers may have to be painted white with blue letters to meet codes.

10-3.2.15 Water Content

Water content in natural gas varies with region. Gas in the Southeast United States is 

usually dry, while gas from West Virginia is very wet. Provide dryers to dry the gas to a 

pressure (storage pressure) dew point (PDP) at least 10 degrees F (6 degrees C) below 

the winter design dry bulb temperature.

10-3.2.16 Design Standards

Design CNG systems to NFPA 52. Use NFPA 54 for the gas supply to the compressor. 

Use the ASME Boiler and Pressure Vessel Code for cascade storage. Electrical work 

must conform to NFPA 70. When collocating CNG and gasoline stations, also use

NFPA 30A. 

10-3.3 Warning

During peak demand periods, some suppliers mix propane air mixtures with natural gas. 

When the amount added exceeds 10 percent by volume, the CNG produced from this 

gas will normally not perform properly in CNG vehicles because propane becomes a 

permanent liquid in storage tanks. Oxygen sensors can be installed to shut down the 
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station during such periods. Installations with this situation should use dual fuel 

vehicles.

10-4 HYDRAZINE STORAGE AND SERVICING FACILITIES

10-4.1 Uses

A blend of 70 percent hydrazine and 30 percent water, known as H-70 fuel, is used to 

operate the F-16 emergency power unit (EPU). The F-16 H-70 tank carries 56 pounds 

(25 kg) of fuel and requires servicing after the fuel has been used. The H-70 tanks are 

removed from the aircraft when the fuel is depleted below a level specified by the using 

activity. The tanks are delivered to the servicing facility where any remaining fuel is 

drained into a closed 55-gallon (210 L) stainless steel drum. The aircraft H-70 tank is 

filled using a closed system charging unit and is either returned to the aircraft or placed 

in a handling/storage container for future use. The bulk H-70 storage tank is a 55-gallon 

(210 L) stainless steel drum containing approximately 51 gallons (190 L) of H-70. 

Nitrogen gas is used as an inert pressure head in the bulk drum to transfer H-70 to the 

charging unit. The charging unit is 75 inches (1900 mm) long by 36 inches (900 mm) 

wide by 92 inches (2340 mm) high and weighs approximately 475 pounds (216 kg). An 

F-16 tactical wing is expected to use approximately 100 gallons (380 L) of H-70 per 

20,000 flight hours with an additional minimum of 150 gallons (570 L) held in reserve to 

handle deployment/safety stock requirements.

10-4.2 General Design Considerations

a) H-70 carries the compatibility group designation of Group C.

b) Separate H-70 fuel storage and liquid/gaseous oxygen storage in 

accordance with AFMAN 91-201. Locate the facility a minimum of 50 

feet (15 m) from aboveground explosive storage in accordance with 

AFMAN 91-201. 

c) Locate the facility a minimum of 100 feet (30 m) from public highways; 

civilian or government living areas; public facilities such as schools, 

churches, clubs, sewage treatment plants; or rivers, lakes, or streams 

because of bio-environmental considerations.

d) Segregate the servicing and storage facility from large population 

concentrations within the confines of a military installation and subject 

to the criteria stated above.

e) Store 55-gallon (210 L) drums of hydrazine in facilities no less than 80 

feet (24 m) apart. The spacing is also subject to the other criteria 

stated in this chapter. This criterion is limited to ten 55-gallon (210 L) 

drums and 20 EPU tanks (provided the tanks are stored inside an 

approved shipping container).

f) Refer to Air Forces AFTO-42B1-1. 
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10-4.3 Construction Concepts

Provide the H-70 facility with space for tank servicing, storage, and personnel hygiene.

10-4.3.1 Access

a) Provide security fencing with a vehicle entrance gate surrounding the 

facility to restrict access.

b) Provide a doorway leading into storage areas to allow for forklift 

access. 

10-4.3.2 Architectural

a) The total area recommended for the facility is 783 square feet (73 m2

) 

with H-70 and N2 bulk storage occupying 210 square feet (20 m2), a 

servicing and storage area of 449 square feet (42 m2

), and a personnel 

area of 124 square feet (12 m2).

b) Provide ceiling height of 12 feet (3.7 m) in storage and servicing areas 

and 8 feet (2.4 m) in personnel areas.

c) Provide hollow, metal, exterior and interior doors with panic hardware 

and automatic closure. Provide double doors, 6 feet (1.8 m) wide to 

allow for equipment movement. Ensure single doors are standard 

size.

d) Provide a rack in the servicing and storage area for vertical drum 

storage (bung side up) to allow for drainage of flush water. Construct 

storage rack of hydrazine compatible materials such as stainless steel, 

plastic, or high-density polyethylene (HDPE).

e) Design floors to permit drainage and prevent collection of liquids on 

any floor surface.

10-4.3.3 Fire Protection Systems

A wet pipe sprinkler system is recommended. Consider above-ceiling detectors, as well 

as room detectors. Provide fire extinguishers of a type approved for use in combating 

hydrocarbon fuel fires in regulated areas. Use AFFF or water. Do not use halogens or 

CO2 extinguishers. Refer to Air Forces AFTO 00-25-172. 

10-4.3.4 Spill Containment

a) Provide spill containment in the H-70 storage area with a capacity 

equal to the larger of 110 percent of the largest drum present or 10 

percent of the total volume present.

b) Spill containment for facilities which store only one or two drums of H70 can be individual containers for each drum.
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c) Provide a diked containment area for facilities which store multiple 

drums of H-70.

(1) Provide ramps for vehicle access.

(2) Provide a coating or liner for concrete containment areas. Do 

not allow exposed iron or rebar in the containment area.

10-4.3.5 Floor Drains

a) Provide a concrete floor in the regulated areas, sloped to floor drains 

which lead to a collection tank.

b) Provide a floor trench drain 18 inches (450 mm) wide by 6 inches (150 

mm) deep by 9 feet (2.7 m) long, covered with an open stainless steel 

grate in the H-70 fuel tank servicing area. The trench is required to 

contain any possible H-70 spillage and periodic draining of the H-70 

servicing stand. Construct the trench parallel to the wall separating the 

storage area from the servicing area. Locate the servicing stand so 

the drain spigot from the scrubber is in-line with the trench drain. A 

polypropylene or polyethylene elbow connection directly from the drain 

spigot to the trench drain is required.

c) Ensure deluge shower and eyewash units in the servicing area drain 

into the containment tank.

d) Ensure industrial sink in the protective equipment room drains into the 

containment tank.

e) Equip drains leading to the containment tank with traps to prevent

vapors from contaminating the area.

f) Provide access to the sanitary sewer for both clean change room and 

shower facilities.

g) Construct floor drains which are subject to carrying H-70 residue of 

polypropylene or polyethylene.

10-4.3.6 Collection Tank and Piping

a) Provide a collection tank and piping of materials compatible with 

hydrazine, water, and neutralizer.

b) Size the collection tank to contain 100 times the maximum quantity of 

H-70 that could spill with a minimum capacity of 1,000 gallons (4000 

L).
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c) Provide piping of 304 stainless steel, HDPE, or to a limited extent, 

galvanized steel.

d) Provide gaskets of suitable materials such as Viton.

e) Test the system annually with water.

10-4.3.7 Grounding

In the storage area, provide a ground strap or grounding point system to ground each 

drum of H-70. Locate the grounding strap around the interior walls of the storage room, 

54 inches (1370 mm) above the floor. The grounding system must have a resistance of 

25 ohms or less. The facility must also have an approved lightning protection system.

10-4.3.8 Hygiene Support Criteria

a) Provide lavatory washing facilities in a non-regulated area close to the 

exit from the regulated area and contiguous to the clean change room.

b) Provide shower facilities for each 10 or less workers.

c) Provide a clean change room. Provide a separate area for the removal 

of contaminated clothing to prevent the spread of potential 

contamination from the regulated area.

d) Provide toilet facilities if the H-70 facility is isolated from other buildings 

where toilet facilities are available.

e) Post signs which state that consumption of food, beverages, 

cosmetics, tobacco products, and chewing materials are prohibited.

10-4.3.9 Lighting

Provide lighting intensities of 50 foot-candles (540 lux) in the servicing area and 30 footcandles (320 lux) in the remainder of the facility. Provide exterior lighting at all 

entrances and security lighting as required.

10-4.3.10 Safety

a) Provide vapor sniffers for use in the H-70 fuel drum storage area and 

servicing area to alert personnel to excessive levels of H-70 fuel 

vapors. Provide sniffers capable of detecting 10 ppb of H-70.

b) A facility respirator air system is recommended. Breathing air shall 

meet at least the minimum Grade D breathing air requirements of 29 

CFR Part 1910.134 and Compressed Gas Association (CGA) 

Pamphlet G-7.1. 
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c) Provide an explosion-proof observation window (4 feet (1.2 m) by 4 

feet (1.2 m)) between the H-70 fuel drum storage area and the tank 

servicing area.

d) All lighting fixtures, electrical outlets, and electrical components located 

within the storage and servicing area should be explosion-proof. 

e) Provide eyewash fountains and deluge shower units within sight of and 

on the same level as locations where direct exposure to H-70 might 

occur. Pipe eyewash and showers to the H-70 collection tank.

f) Post signs at entrances to all areas. Signs should warn personnel that 

“H-70 is a cancer suspect agent,” “Authorized Personnel Only,” and 

“No Smoking.”

g) All tools and equipment must be constructed of hydrazine compatible, 

rust-free, corrosion-resistant materials.

10-4.3.11 Utilities

a) For electricity, provide 120-VAC, 60-Hz, single phase, three-wire, 20 

amperes, duplex convenience outlets in each area of the facility 

(minimum six outlets). Two-way switching is preferred to control 

lighting in the H-70 fuel drum storage area from the H-70 fuel tank 

servicing area. Provide explosion-proof, Class I, Division 2, Group C 

electrical fixtures.

b) Provide 15 gpm (1.0 L/s) hose bibb water outlets with backflow 

prevention. Size hose bibb for standard lawn hose connections. 

Locate the hose bibb to provide water to service stand on the inside of 

the exterior wall, on the center of the servicing trench, about 2.5 feet 

(0.8 m) above the finished floor (below the 4-inch (100 mm) pipe 

sleeve). Water with a reduced pressure-type backflow preventor will 

also be required for the fire suppression system and potable water 

systems. 

10-4.3.12 Ventilation

a) Segregate mechanical ventilation for regulated versus non-regulated 

areas. Exhaust regulated areas through a common manifold. 

Evaluate the need for an air pollution control system on a case-by-case 

basis and consider federal, state, or local emissions criteria applicable 

to the construction location.

b) Design ventilation systems for regulated areas to maintain a negative 

pressure of 0.05 to 0.1 inches of water (12 to 25 Pa) with respect to 

adjacent non-regulated areas.
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c) Design ventilation for servicing and storage areas to provide a 

minimum of 20 air changes per hour.

d) Design the ventilation system for automatic shutdown in the event of a 

fire within the facility.

e) Use flexible exhaust vent of the “elephant trunk” type to exhaust 

vapors that are released when full hydrazine drums are opened. 

Design for air flow at the vent nozzle to be approximately 150 cfm (71 

L/s). Refer to American Conference of Governmental Industrial 

Hygienists (ACGIH), Industrial Ventilation: A Manual of Recommended 

Practice for Design. 

f) Place exhaust ports at approximately 18 inches (450 mm) above the 

floor. To avoid exhausting H-70 vapors into areas where personnel 

are present, such as walkways or escape paths, consider placing 

exhaust ports above the roof line.

g) Place a switch on the outside of the building, near an entrance that will 

allow personnel to turn on all exhaust fans prior to entering the facility 

This will purge the facility of any H-70 vapors that may have collected 

in the facility while not in use.

h) Maintain temperature in regulated areas below 120 degrees F (49 

degrees C). Provide environmental controls consistent with ventilation 

for personnel comfort.

10-4.3.13 Waste Product Disposal

a) Add water to H-70 spills in a 100 to 1 ratio to reduce the H-70 

concentration to less than 1 percent. Size collection tank accordingly.

b) Use neutralizers, such as 65 percent granular calcium hypochlorite 

(HTH), 14 percent bleach, and 5 percent bleach to stabilize the H70/water mixture.

c) Provide storage for HTH away from hydrazine and other potentially 

reactive materials. HTH is extremely corrosive.

d) Consult with local base bio-environmental engineer as to procedures 

for emptying the collection tank.

10-5 OTTO FUELS

Information on OTTO fuels is contained in NAVSEA S6340-AA-MMA-010. Distribution 

of this document is restricted. Requests for information are handled by Naval Sea 

Systems Command. Refer to Chapter 2 of this UFC for additional information.
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CHAPTER 11 - SUPPORT FACILITIES

11-1 INTRODUCTION

This chapter provides design criteria for facilities which may be required to support 

fueling activities. Specifically, operations buildings, contaminated fuel recovery 

systems, roads, utilities, and aircraft refueler parking areas are detailed in this chapter.

11-2 OPERATIONS BUILDING

Review the fueling activity to establish a need for each component of this building. 

Factors which will affect these reviews are number of people required for fueling activity, 

level of activity, types of fuels handled, on-site quality control, availability of replacement 

parts, availability of maintenance support, and level of training required.

11-2.1 Design Standards

The support facilities shall be designed in accordance with UFC 1-200-01, General 

Requirements. See UFC 3-600-01 for fire protection requirements.

11-2.2 Fuel Office

Provide a fuel office with sufficient space to perform the necessary planning, 

administrative, and management functions associated with the accomplishment of the 

fuel division’s mission. Refer to AFH 32-1084 for size on Air Force projects.

11-2.3 Training/Conference Room

Provide a multipurpose room with equipment for training, conferences, and briefings. 

Design this room to accommodate furniture and have built-in features such as 

markerboard, tack board, book shelves, screen, clock, coat hooks, and storage 

cabinets.

11-2.4 Fuel Maintenance Workshop

Provide a fuel maintenance workshop with an adequately sized and convenient work 

bench with compressed air and electrical outlets available. Provide slip and fuelresistant floor, emergency shower/eye wash, and adequate storage space adjacent to 

the workbench for frequently used tools, spare hardware items and accessories. If 

facility is large enough and mission warrants, consider overhead crane, laundry facility, 

and shower facility. Refer to Chapter 2 of this UFC for electrical hazard classification 

and requirements and NFPA for ventilation requirements.

11-2.5 Storeroom

Provide an adequate storeroom for spare hoses, nozzles, filtration elements, special 

tools, special clothing, test equipment, and fuel spill clean-up equipment. Determine 

size and location of each facility to provide sufficient space for orderly storage and 

location for ready access to needed material by fuels division personnel.

11-2.6 Laboratory

Laboratories shall comply with the general facility requirements of UFC 3-600-01 and 

NFPA 45 Laboratories using Chemicals. The fuel laboratory size and associated 

equipment depend on the scope of the quality surveillance and testing program 
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performed. Design the laboratory in accordance with applicable NFPA and CFR codes. 

Review NFPA 45 for applicability. Minimum laboratory requirements are as follows:

a) Lighting and fixtures in accordance with NFPA 70. 

b) Sink with running hot and cold water. Include hot water heater capable 

of providing water at 130 degrees F (54 degrees C) for cleaning 

laboratory glassware.

c) Work bench(s) or counter(s) of sufficient size to accommodate and 

maintain all required test equipment in a ready-to-use position. 

Compose countertops of a non-permeable material suitable for working 

with petroleum fuels. Ensure that laboratory flooring material is 

impermeable and suitable for a fuels laboratory.

d) Storage cabinets for test equipment support items; for example, 

bottles, drying rack, and spare millipore pads. Construct cabinets of a 

non-permeable material suitable for exposure to petroleum fuels.

e) Fume hood, comply with 29 CFR Part 1910.1450, Appendix A. 

Electrical equipment located inside the fume hood shall be rated for 

classified areas.

f) Emergency eyewash/shower. Construct adjacent walls of 

waterproof/water-resistant materials.

g) Outward opening doors with panic bars. Multiple doors may need to 

be provided in accordance with NFPA 45. 

h) Portable firefighting equipment.

i) Telephone.

j) Fire alarm box.

k) A waste tank or means to dispose of fuel samples.

l) Lighted exit signs.

m) Capabilities to maintain laboratory at 73 degrees F (23 degrees C) plus 

or minus 5 degrees F (3 degrees C). (Required to protect laboratory 

equipment.)

n) Bonding and grounding of all metal working surfaces and electrical 

equipment. Also, provide a common static grounding strap or 

approved grounding points readily accessible to all fixed working 

surfaces and alongside entrance doors.

o) Recessed floor to prevent spilled fuel from flowing into adjacent areas.
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p) Windows constructed of fireproof materials. Draperies and curtains 

are prohibited. If interior windows are provided, use translucent 

reinforced safety glass.

q) An HVAC system designed so that air from the laboratory does not 

recirculate to other portions of the building.

r) Interior separations from other portions of the building with a partition 

rated for fire separation as required by NFPA 45. 

s) Type “N” unprotected non-combustible construction.

t) Provide a location and connections for an automatic laboratory 

glassware washer.

u) Electrical installations in the laboratory work areas are non-classified. 

11-2.7 Miscellaneous Safety Equipment

Provide firefighting, fire alarm, and emergency eyewash/shower equipment. Provide 

emergency eyewash/shower with tempered water in cold weather climates. Also see 

applicable service-specific guidelines.

11-2.8 Control Room

Where computerized control equipment is anticipated, provide a control room of 

adequate size and with a maximum view of outside activities. Allow extra space along 

the ceiling/wall interface for future installation of security monitors. Consider electrical 

receptacles and data outlets for future use.

11-2.9 Miscellaneous Spaces

Provide toilets, shower facilities, lockers, dressing rooms, mechanical room, electrical 

room, janitor closet, break room, etc. based on the size of the facility and the planned 

activities. Provide exhaust for locker rooms through the back or top of the lockers.

11-2.10 Communications

Make provisions for telephone, data transmission, and other planned communications 

equipment.

11-3 ROADS

Design roads within a fueling facility to accommodate maintenance activities, operations 

personnel, and fuel delivery and/or issues. In addition, evaluate the roads leading to the 

facility for their adequacy of width, access, geometrics, and weight restrictions. For 

vehicle access roads in diked areas around tanks, see Chapter 8 of this UFC. Refer to 

UFC 3-250-18FA and UFC 3-250-01FA for design guidance.

11-4 UTILITIES

In most cases, a fueling facility requires water (domestic and fire protection), sanitary 

sewer, storm sewer, and electricity.
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11-5 AIRCRAFT REFUELER AND FUEL DELIVERY VEHICLE PARKING 

11-5.1 General

Ensure aircraft refueler and ground fuel delivery vehicle parking areas meet the 

following criteria at a minimum. For additional design guidance, refer to NAVAIR 00-

80T-109 and Air Force AFTO 00-25-172. 

11-5.2 Clearances

a) Provide a minimum of 25 feet (7.6 m) between the centerlines of 

adjacent aircraft refueler trucks and ground fuel delivery vehicles when 

in the parked position or 10 feet (3 m) minimum of clear space 

between parked trucks, whichever is greater.

b) Provide a minimum of 50 feet (15 m) between aircraft refueler/ground 

fuel delivery vehicle parking area and the following:

(1) Uninhabited building for new projects.

(2) Pump house or filter/separator building.

(3) Taxiing aircraft.

(4) Fence, if space is a limitation (100 feet (30 m), if space is 

available).

(5) Roads outside of a security fence.

(6) Overhead power and communication lines.

(7) Pad-mounted transformers.

(8) Parked aircraft.

(9) Any building other than a maintenance building.

c) Provide a minimum of 100 feet (30 m) between aircraft refueler/ground 

fuel delivery vehicle parking area and the following:

(1) Inhabited buildings.

(2) Aboveground Storage Tanks

(3) Truck or tank car off-loading station.

(4) Truck fillstation.

(5) Property lines.
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(6) Highways.

(7) New POL Operations Building.

(8) Airport surface detection radar equipment.

d) Provide a minimum of 300 feet (90 m) between an aircraft 

refueler/ground fuel delivery vehicle parking areas and the following:

(1) Aircraft warning radar antennas.

(2) Areas where airborne surveillance radar may be operated.

e) Provide a minimum of 500 feet (150 m) between an aircraft

refueler/ground fuel delivery vehicle parking areas and airport ground 

approach and control equipment.

f) Provide a distance as great as practically possible between an aircraft 

refueler/ground fuel delivery vehicle parking areas and radio 

transmitting antennas.

g) Contact the installation safety office to obtain distance criteria from an 

aircraft refueler/ground fuel delivery vehicle parking areas to aircraft 

carrying explosive materials.

11-5.3 Arrangement

The preferred arrangement is parallel positions, but “front-to-back” and variations of the 

two are acceptable. Provide “front-to-back” clearance between vehicles such that the 

aircraft refueler/ground fuel delivery vehicle in the “back” position would not have to 

back-up to pull out of the parking position. This distance will vary according to the 

turning radius of each aircraft refueler/ground fuel delivery vehicle. Arrangement should 

satisfy functional requirements of users and provide for safe operation and efficient use 

of available space. Provide for parking of all refueling vehicles expected to use this 

facility and include identification of positions.

11-5.4 Ingress/Egress

Provide for “drive-ahead” motion of vehicles at all stages to avoid backing up vehicles 

under normal circumstances. Provide for smooth and efficient movement from the truck

fillstand area to the parking positions and from the parking positions to the aircraft 

apron. Where necessary, provide adequate markings to ensure safe and efficient 

vehicle movements. At a minimum, provide two means of ingress/egress.

11-5.5 Paving

Use concrete pavement, capable of withstanding design vehicle wheel loads. Seal 

joints with fuel-resistant materials. For circulation pavements, provide bituminous 

flexible pavements unless an economic analysis shows rigid concrete is more costeffective. Use concrete pavement in aircraft refueler/ground fuel delivery vehicle

parking areas.
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11-5.6 Containment Area

Provide a containment area consisting of an impermeable retention and controlled 

drainage system leading to a concrete remote spill containment system. Pave the area 

with concrete pitched a minimum of 1 percent toward catch basins or trench drains. 

Design the containment area in accordance with UFC 1-200-01, federal, state, and local 

regulations. Do not use asphalt within a spill containment area. The maximum slope of 

any paving within a truck movement or parking area shall not exceed 2 percent 

excepting rollover curbs. If a rollover curb is provided, the sum of the vertical entrance 

and exit grades shall not exceed 8 percent, the horizontal length of the curb in the 

direction of truck movement shall not be less than 15 feet, and the rollover curb shall be 

aligned perpendicular with direction of truck movement. 

11-5.7 Remote Spill Containment System

Provide a concrete remote spill containment system. Design the spill containment 

system in accordance with UFC 1-200-01, federal, state, and local regulations. Provide 

the remote spill containment system with capacity greater than either the volume of the 

largest aircraft refueler/ground fuel delivery vehicle to be parked or runoff from a rainfall 

of intensity equal to a 5-year expectancy, 1-hour duration storm. Provide a lockable 

knife gate valve with indicator post located outside the enclosure in an area that will be 

safely accessible during a fire. The valve on the drain system shall be lockable and 

normally closed to allow for containment during fueling operations and which can be 

opened to drain the area when necessary. Tank trucks can be as large as 10,000 

gallons (38 000 L) in capacity. Consider combining the remote spill containment system 

with other remote spill containment systems on site, except with tank containment 

systems. However, take the level of contamination in each containment area into 

consideration. Construct the drain lines between the containment area and the remote 

spill containment system, and between the remote spill containment system and the 

lockable knife gate valve of petroleum-resistant, fire-resistant, impervious material; do 

not use clay, concrete, fiberglass or plastic piping materials.

11-5.8 Fire Protection

Refer to Chapter 2 of this UFC for fire protection requirements.

11-5.9 Security

Provide fencing and lighting for security as required in Chapter 2 of this UFC.

11-5.10 Lighting

Provide 1-footcandle (10 lux) lighting to ensure that a fuel leak from the refueler is seen.

11-5.11 Block Heater Connections

At facilities where aircraft refuelers/ground fuel delivery vehicles have block heaters, 

provide connections for those heaters.
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CHAPTER 12 - MAJOR REHABILITATION

12-1 INTRODUCTION

Decisions concerning major rehabilitation will be based on economics, mission, safety, 

or environmental factors. It is not the intent of this chapter to mandate rehabilitation, but 

only to provide guidance if the decision is made. The most common reasons for 

rehabilitation are to meet environmental needs or to extend the usable life of the facility. 

If a tank or major component is taken out of service for rehabilitation, review other 

chapters of this UFC. However, consider each change based on its merits and its 

compliance with this UFC. It is not the intent of this UFC to initiate changing and 

upgrading of existing facilities. Before initiating a facility improvement or major 

rehabilitation fuel project, it is recommended that a Physical Condition Survey be 

conducted to survey the condition of the facility with the goal of identifying major 

deficiencies and prioritizing the work required. Contact the appropriate Command Fuels 

Engineer, Naval Facilities Engineering Component Commands and the Naval Facilities 

Engineering Service Center, or Army Corps of Engineers regional design office. For 

Naval Air Stations and Marine Corps Air Stations, include a representative from 

NAVAIR on the survey team. In most cases, coordinate major rehabilitation proposals 

with the base master plan.

12-2 GENERAL REQUIREMENTS

Chapter 2, General Design Information, contains important information on fueling 

facilities. Do not begin the design or modification of any fueling system without first 

becoming completely familiar with Chapter 2 of this UFC.

12-3 ABOVEGROUND FUEL STORAGE TANK REHABILITATION

Existing aboveground storage tanks can be modified to meet fuel quality standards, 

safety requirements, and environmental regulations. To maintain the structural integrity 

of aboveground storage tanks and to ensure a complete and usable facility, ensure all 

designs are accomplished by an engineering firm regularly engaged in tank modification 

or have all plans and specifications reviewed by an API Std 653 certified inspector. 

Complete all tank modifications, repairs, alterations, or inspections in accordance with 

API Std 653 and API Std 650. Require a new strapping table after any major tank 

rehabilitation.

12-3.1 Aboveground Vertical Tank Inspections

Prior to modifying the tank, conduct a thorough inspection consistent with the 

requirements of API Std 653. This inspection will reveal any repairs that need to be 

made in order to comply with current regulations. 

12-3.2 Increase Manhole Sizes

Many older aboveground vertical tanks have inadequately sized shell manholes. The 

ventilation and equipment requirements for maintenance have created a need for 36-

inch (900 mm) diameter manholes. If they do not exist, consider rehabilitation. Provide 

in accordance with Chapter 8 of this UFC.
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12-3.3 Replace Tank Floors

Replace existing tank floors only when an API Std 653 inspection (including a magnetic 

flux leakage test) indicates that the useful life of the bottom has expired, or that the

bottom requires more than minor repairs or upgrades, or if significant fuel quality

problems due to ponding water exist. Contact Service Headquarters for guidance. 

Whenever a tank bottom is replaced it shall comply with current design standards 

including either a double bottom or single bottom with liner. In no case shall a tank with 

a single bottom remain in service when the bottom warrants replacement, unless other

provisions such as a programmed MILCON or SRM project has been approved to 

replace the tank and/or bottom. Conduct an analysis of the existing tank and local 

conditions to determine the most desirable approach. The type of new bottom to be 

installed depends upon a number of factors, including: condition of the existing bottom, 

tank foundation, shell condition, and amount of tank capacity which can be “lost.” Install 

double bottoms or replacement bottoms in accordance with API Std 653. Install sloped 

bottoms (3 to 5 percent) either above the existing bottom if the user can accept the 

resulting loss in tank capacity or remove the existing bottom and install a new sloped 

bottom in its place. A slope of 5 percent is preferred, but not required. If conditions and 

cost make the recommended slope impractical, provide a minimum slope of 2 percent. 

In either case, install an impermeable liner in accordance with DoD Standard Design 

AW 78-24-27, as well as leak detection between the two floors. The technology exists 

and it may be cost effective to raise the tank off its foundation to accomplish under tank 

modifications or repairs (e.g., adding containment liner/tell-tale system, cathodic 

protection, ringwall, etc.).

12-3.3.1 Double Bottom With Washed Sand Layer and Liner

Clean and repair the existing tank bottom, install a liner on top of the existing tank 

bottom, add a 4- to 6-inch (100 to 150 mm) silica sand layer on top of the liner, and 

install the new steel tank bottom on top of the sand layer. Refer to Chapter 8 of this 

UFC for suitable sand criteria. Leak detection consists of tell-tale slotted PVC pipes 

within the sand layer at regularly spaced intervals and extending out through the outer 

shell of the tank. Provide cathodic protection by sacrificial anodes or impressed current 

close to the liner to allow maximum clearance from the new tank bottom. Install 

adequate numbers of a cathodic protection reference cells between the two bottoms.

12-3.3.2 Double Bottom With Concrete Layer and New Steel Bottom

Clean and repair the existing tank bottom, install a liner on top of the existing tank 

bottom, pour 4 to 6 inches (100 to 150 mm) of fiber reinforced (low slump mix - typically 

3,000 psig (21 000 kPa)) concrete over the liner and existing bottom, shape the 

concrete to provide adequate slope, and install the new steel tank bottom on top of the 

concrete. Slope the concrete towards a sump and form with a series of grooves along 

the top surface to collect any product which may leak through the new bottom. Slope 

the channels to a collection point with a pipe extending to an observation well. Provide 

concrete with an alkalinity of 13 or higher.

12-3.3.3 Double Steel Bottom

Clean and repair the existing tank bottom, place a structural support system on top of 

the existing tank bottom, and install the new tank bottom. Design the structural support 
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system to prevent excessive deflections resulting from loads on the primary (new) tank 

bottom. Allow for an interstitial space between the two tank bottoms to detect and 

collect any product from a leak. Purge the interstitial space between the two bottoms 

with nitrogen to remove the oxygen, thus creating a non-corrosive, non-combustible 

environment. The elimination of condensation and oxygen within the space minimizes 

corrosion formation for the upper (new) bottom. Provide leak detection with sensors 

which can detect pressure changes within the space. A pressure increase results from 

a leak in the upper tank bottom as product enters the space. A decrease in pressure 

indicates a leak or steel failure has occurred in the lower tank bottom.

12-3.3.4 Single Bottom With Liner

Remove the existing tank bottom and prepare the sub-base for bearing capacity. Place 

sand layer on the sub-base to support the primary tank bottom, install a liner with a 

slope to a center liner sump, place a minimum 12-inch layer of sand on top of the liner, 

and install a new tank bottom on top of the sand layer. The liner sump is the collection 

point for any leaks from the bottom and consists of a drain pipe leading to an 

observation well. An alternative method is to use tell-tale slotted PVC or stainless steel 

pipes in accordance with DoD Standard Design AW 78-24-27. Provide cathodic 

protection by sacrificial anodes or impressed current close to the liner to allow maximum 

clearance from the new tank bottom. Install adequate numbers of a cathodic protection

reference cells between the two bottoms. Place cathodic protection in the sand layer 

approximately 6 inches (150 mm) below the new tank bottom and above the liner.

12-3.4 Replace Floating Roof Tanks With Fixed Roofs

If a floating roof requires significant repair work, is corroded beyond economic repair, or 

for any reason is considered unserviceable (by an API Std 653 inspection), consider 

replacing it with a fixed cone roof and internally sealed honeycomb cell floating pan, as 

required in paragraph 2-15.2. When a fixed cone roof is added to an existing tank the 

roof manufacturer and the designer must determine that the tank has sufficient strength 

to support the new roof. If the shell is structurally insufficient, a geodesic dome may be 

considered. Install structural supported roofs in accordance with API Std 650, API Std 

653, and DoD Standard Design AW 78-24-27. In general, all open top, floating roof 

tanks containing aviation fuel should be programmed to receive a cover, as should all 

tanks in northern climates where snow and ice is a problem. 

12-3.5 Product Recovery Systems

Provide storage tanks with pumps, piping, valves, and tanks to collect, recover, and 

return usable aviation turbine fuel which would otherwise become waste. Include a 

tank(s) to collect fuel/water mixtures from tank and equipment sumps, equipment 

drains, high point vents, low point drains, and any other equipment from which 

fuel/water mixtures can be collected. Separate the fuel and water portions. Filter the 

fuel portion and return to bulk storage tanks. Do not discharge the water portion to 

surface water without additional treatment and permits or treat the water portion as 

wastewater. Refer to Chapter 2 of this UFC for information on handling of wastewater. 

Design in accordance with DoD Standard Design AW 78-24-27.
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12-3.6 Coatings

In tank coating projects, minimize the generation of hazardous waste associated with 

coating removal. Some alternatives to traditional sand blasting include shot “blasting”, 

chemical stripping, high pressure water, carbon dioxide, or chemical stabilizer additive

process. Designs for maintenance painting, both interior and exterior, should be based 

on a coating condition survey, as discussed in the notes to UFGS 09 97 13.15, 09 97

13.17, and 09 97 13.27. An evaluation of shell coating should be based not only on 

condition but on the need for coating the shell and an evaluation of apparent corrosion

pressures on the shell. Corrosion pressure on shell coatings is generally fairly low; 

therefore, there is not the same need for coating thickness and integrity that is required 

for floors and ceilings. Refer to Chapter 8 of this UFC for additional information on 

interior and exterior coatings for storage tanks. Re-coat the portion of the tank that is 

already coated. When tanks are taken out of service for inspection or repairs, inspect 

the underside of the roof for rust. If conditions merit, coat the underside of the roof in 

conformance with Chapter 8 of this UFC.

12-3.7 Isolation Valves

Require tank isolation valves to prevent the accidental release of fuel into the 

environment. On aboveground tanks larger than 12,000 gallons, provide double block 

and bleed tank shell valves located between the tank shell and the high level shut-off 

valve.

12-3.8 Alarms and High Level Shut-off Valves

Equip storage tanks with a means to prevent accidental overfill. Design in accordance 

with DoD Standard Design AW 78-24-27. Refer to Chapter 8 of this UFC for applicable 

requirements for alarm and valve installation.

12-4 UNDERGROUND OPERATING TANKS

If major rehabilitation is required, upgrade existing underground operating tanks to 

conform with 40 CFR Part 280 and 40 CFR Part 281 and applicable state and local 

underground storage tank regulations. As a minimum, provide leak detection, cathodic 

protection, and overfill protection. Careful study of cut and cover tanks is necessary 

since construction features may make it impossible to comply.

12-4.1 Manholes

Provide a 36-inch (900 mm) diameter manhole for tanks. Extension necks and internal 

ladders are required for cleaning and inspection. Provide a minimum of one manhole 

for tanks between 1,000 gallons (4000 L) and 5,000 gallons (19 000 L). Provide a 

minimum of two manholes for tanks larger than 5,000 gallons (19 000 L). Provide 

manhole containment sumps for all manholes.

12-4.2 Interior Coatings

Coat underground operating tanks in accordance with Chapter 8 of this UFC.

12-5 HYDRANT SYSTEMS

Decisions concerning major rehabilitation of existing direct aircraft refueling systems will 

be made by Service Headquarters. This paragraph addresses existing direct aircraft 
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refueling systems (Type I and Type II) which can be rehabilitated or modified to meet 

fuel quality standards, safety requirements, mission requirements, and environmental 

regulations. All designs should be accomplished by an engineering firm regularly 

engaged in the design of direct aircraft fueling systems. The provisions of Chapter 4 of 

this UFC are applicable.

12-5.1 Pumps

Repair or replace existing pumps to meet increased fuel demands. Rebuild pumps 

including complete bearing replacement, additional bowls or increased impeller size, 

replacement of mechanical seals, shaft lengthening or shortening to match replacement 

tanks, etc. In some cases, additional capacity can only be achieved by total pump 

replacement or rearrangement of piping. Consider pump replacement where, due to 

equipment age or condition, it is more economical to replace than to rebuild. Pump and 

motor replacement may also result in higher efficiency units with lower power demands 

and increased spare part availability.

12-5.2 Filter/Separators

Existing filter/separators must be capable of meeting requirements of EI Specification 

1581 (Edition 5). Existing filter/separator vessels built to earlier editions of API 1581 

may be able to be reutilized with EI Specification 1581 (Edition 5) coalescer and 

separator elements. Where possible, the replacement elements should meet the 

standard sizes described in DESC-X-P-2. Contact the Service Headquarters for 

guidance. Replace existing vessels if they cannot be converted to use EI Specification 

1581 (Edition 5) elements or if the vessel with EI Specification 1581 (Edition 5) 

elements fails to meet quality standards. Issue filter/separators should be given priority 

for upgrade on a stand-alone project. Upgrade of all filter/separators is mandatory on 

any major rehabilitation project.

12-5.3 Fuel Quality Monitors

Existing fuel quality monitors will be removed. Fuel quality monitor elements degrade 

when they come in contact with fuel additives (FSII) in aviation turbine fuel causing fuel 

quality issues. 

12-5.4 Control Systems

Pump houses and hydrant systems typical of the Panero (circa 1952) and Pritchard 

(circa 1958) designs utilize hard-wired, high-voltage mechanical relays. Control 

systems installed from the pump house to the lateral control pits, emergency stops, and 

pit activation switches are typically high voltage. Age, elements, and exposure to fuels 

may deteriorate control system wiring and render it no longer reliable or safe to operate. 

Consider control system replacement whenever a significant portion of the pump house 

is repaired or when fire, safety, or electrical codes indicate a hazard exists. Generally, 

hard-wired relay logic systems are expensive to build and maintain and do not offer the 

flexibility of PLC based systems. Control systems should be of low voltage design 

incorporating industry standard PLCs. If control facilities are isolated from the pump 

house (not subject to atomized fuel) and the facility has positive ventilation, then nonexplosion-proof fixtures may be incorporated into the design. Existing control wiring has 

probably deteriorated and numerous conduits are no longer intrinsically safe. Replace 
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control wiring and wherever possible run control wiring in overhead conduit. If 

necessary, replace kill switch and emergency stop circuits as part of the pump house 

rehabilitation. Cable wiring systems are easier to install and troubleshoot and should be 

considered whenever the wiring to hydrant system is replaced.

12-5.5 Electrical Systems

Replace secondary electrical systems, including lighting and motor conductors and 

motor control centers, as part of pump house repairs. Ensure circuits within the pump 

house, exposed to the possibility of atomized fuel, comply with the provisions of NFPA 

30 and are classified Class I, Division 1. If the motor control center is isolated from the 

pump house (not subject to atomized fuel) and the facility has positive ventilation, then 

the area may be derated and non-explosion-proof lighting fixtures may be incorporated 

into the design. Existing secondary wiring has probably deteriorated and numerous 

conduits are no longer intrinsically safe. Replace motor wiring and wherever possible 

run control wiring in overhead conduit.

12-5.6 Lateral Control Pits

Lateral control pits are typically concrete structures with heavy metal-hinged lids 

containing valves, pumps, filters, and piping associated with the supply of fuel from a 

pump house to a hydrant outlet. Repair or replace pits to prevent the accidental release 

of aviation turbine fuel to the environment and water infiltration. Slope pit floors to a 

sump and provide manually operated sump pumps to aid in water removal. Use either 

rolling or light-weight hinged aluminum pit lids with a water-tight design. Comply with

DoD Standard Design AW 78-24-28.

12-5.7 Distribution Piping

Minimize the use of unlined carbon steel pipe, especially with jet aircraft. A number of 

alternatives exist which reduce the exposure of aviation turbine fuel to unlined carbon 

steel pipe. One option is to internally coat existing systems without pipe removal. Insitu coatings can prevent fuel degradation; however, final filtration must still be provided 

at the aircraft by either a mobile or fixed filter/separator. Another option is to sleeve the 

piping with a non-ferrous material (stainless steel). Consider this option if reduced flow 

rates are acceptable.

12-5.8 Diaphragm Control Valves

Consider reusing existing diaphragm control valves wherever possible. Diaphragm 

control valves can typically be refurbished by either the original manufacturer or by a 

factory authorized repair facility for less than the replacement cost. Ensure refurbishers 

modify or replace pilot assemblies, tubing, and solenoids to meet specifications as 

outlined in DoD Standard Design AW 78-24-28. As a minimum, replace non-ferrous 

pilot tube assemblies with a stainless steel unit. Provide stainless steel control tubing 

and replace all internal valve components. If the valve body is carbon steel, request 

Service Headquarters to determine if the valve body should be sand-blasted and 

cleaned or replaced. Coat or plate carbon steel bodies to meet DoD Standard Design 

AW 78-24-28.
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12-5.9 Hydrant Outlets

Remove and replace existing hydrant outlets and connections (e.g., Buckeye) with API 

adapters. Conversion to API adapters ensures compatibility with all refueling 

equipment. If adequate pressure control (regulating and surge) in accordance with DoD 

Standard Design AW 78-24-28 does not exist at the hydrant pit or at the lateral control 

pit, then install a control valve at either location.

12-6 DIKES, LINERS, AND BASINS

If dikes, liners, and basins do not comply with the requirements of this UFC, 40 CFR 

Part 112, state, or local spill containment regulations and the potential for accidental fuel 

discharges exists, repair or replace the existing structures. The provisions of Chapter 8

of this UFC are applicable. In general, if the dike does not retain rainwater, 

improvements are necessary.

12-7 LEAK DETECTION

When rehabilitating fuel facilities, install leak detection, if necessary, as detailed in 

Chapter 2 of this UFC.

12-8 CATHODIC PROTECTION

When rehabilitating any fuel facility, install or upgrade cathodic protection. Ensure 

cathodic protection systems are designed by a NACE certified Corrosion Specialist or 

Cathodic Protection Specialist or a registered professional Corrosion Engineer. Install 

cathodic protection on all steel structures including, but not limited to, aboveground 

storage tanks, underground storage tanks, and underground piping systems. The 

provisions of Chapters 2 and 8 of this UFC are applicable.

12-9 ISOLATION VALVES

Provide valves in product piping systems to control flow and to permit isolation of 

equipment for maintenance or repair. Provide additional valves at required locations 

necessary to conduct a valid hydrostatic test. Provide manually operated valves, except 

where motor operators are specifically authorized by applicable standard drawings or 

technical specifications. Use double block and bleed type isolation valves for 

separation of product services, on tank shell connections (ASTs over 12,000 gallons 

only), when piping goes above or below ground, between pier and tank storage, and 

other locations critical to periodic pressure-testing of piping. Quick opening/frequent 

opening type isolation valves may be used for less critical applications where double 

block and bleed shutoff is not required. Before adding isolation valves, evaluate piping 

system and make modifications to prevent pressure buildup caused by thermal 

expansion. Review paragraph on relief valves in Chapter 9 of this UFC. Except for 

those serving tactical refueler fillstands, this paragraph does not apply to systems 

covered by Chapter 7 of this UFC unless otherwise directed by Service Headquarters.

12-10 SOIL AND GROUNDWATER REMEDIATION

Monitor, store, and dispose of petroleum-contaminated soil disturbed during 

rehabilitation in accordance with state and local environmental regulations. Collect, test 

(if appropriate), and treat petroleum-contaminated groundwater removed during 

dewatering by one of the following methods:
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a) Off-site disposal at an industrial waste facility.

b) On-site treatment with a portable groundwater treatment system.

c) Treatment through an oil/water separator. 

d) Treatment through the sanitary sewer.

Prior to selecting a treatment method, review state and local environmental regulations 

and consult the facility for acceptable alternatives and permits required for on-site 

treatment and disposal.

12-11 LIQUEFIED PETROLEUM GAS (LPG) FACILITIES

When rehabilitating an LPG facility, back weld (seal weld) all existing threaded piping.

12-12 PIPELINE INSPECTION

12-12.1 Inspection

Conduct pipeline inspections in accordance with API 570 and NACE SP0169. 

12-12.2 Smart Pigging

To determine if or how a pipeline requires rehabilitation, information on the pipeline’s 

structural integrity is essential. One method to survey the condition of the pipeline is to 

use smart pigs.

12-12.2.1 General

A “smart” or “intelligent” pig is one of a variety of instrumented tools using one or more 

physical or electro-mechanical principles for recording and measuring information for 

positioning and relative severity of anomalies in a pipeline. Smart pigs can detect 

cracks, metal loss, and curvature/bends. Other types available can map and profile 

pipe, detect leaks, perform photographic inspection, and sample product. Use of smart 

pigs may require modifying the pipeline to increase the radius of sharp elbows and 

eliminate obstructions caused by valves that are not full port type.

12-12.2.2 Types

The three basic types of smart pigs are ultrasonic, magnetic flux leakage (MFL), and 

eddy current. Ultrasonic, MFL, and eddy current pigs can be used in liquid pipelines. 

An alternative form of ultrasonic inspection is an electromagnetic acoustic transducer 

(EMAT). An EMAT can be used in either a liquid or gas pipeline. MFL can also be 

used in gas pipelines. Prior to choosing a smart pig, consider expected results, cost of 

various options, and expected pipeline condition.

12-13 CHECKLIST

The following is a checklist of items to be considered in a major rehabilitation.

a) Aboveground storage tank rehabilitation

(1) API Std 653 inspection.
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(2) 36 inch (900 mm) diameter manholes for maintenance.

(3) Add double bottom.

(4) Repair and slope tank floor.

(5) Repair or replace floating roof.

(6) Product recovery system.

(7) Internal and external coating systems.

(8) Tank isolation valves.

(9) Fill and overfill protection.

(10) Corrosion protection to tank bottom.

(11) Leak detection.

(12) Automatic tank gauging system.

(13) Thermal expansion relief.

b) Underground storage tank rehabilitation

(1) 36 inch (900 mm) diameter manhole(s).

(2) Leak detection.

(3) Corrosion protection.

(4) Overfill protection.

(5) Interior coating.

c) Aviation/Hydrant system rehabilitation

(1) Repair or replace pumps to API Std 610. 

(2) Upgrade filter/separators to comply with EI Specification 1581

(Edition 5). 

(3) Remove automatic water drains from filter separators.

(4) Repair or replace control systems.

(5) Repair or replace electrical systems.
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(6) Repair or replace lateral control valve pits and lids, including an 

impervious liner.

(7) Internal coating to carbon steel distribution pipe.

(8) Refurbish diaphragm control valves.

(9) Hydrant outlets to API adapters.

(10) Replace lubricated valves and swivels with non-lubricated.

d) Truck fill/off-load stands

(1) Grounding, deadman, and high level shut-off systems.

(2) Pantographs - convert from 3-inch to 4-inch (75 mm to 100 mm).

(3) Low profile filters.

(4) Fusible link butterfly valves (These valves are not required nor 

permitted on Air Force projects).

(5) Piping of pressure reliefs to contained tank.

(6) Updated meters and meter diaphragm control valves.

(7) Adequacy of piping and system grounding. 

(8) Adequacy of spill collection and containment.

(9) Upgrade military specification filter separators to comply with EI 

Specification 1581 (Edition 5). (Issue filters have priority over 

receipt filters.)

(10) Remove automatic water drains on filter/separators and ensure 

that any liquid drained from separators is properly handled.

e) Add isolation valves and blind flanges throughout system.

f) Use smart pigging to determine the condition of the distribution piping.

g) Monitor, remove, and dispose of petroleum-contaminated soil and 

groundwater.

h) Spill Containment and collection.

(1) Concrete containment areas for dikes, equipment pads, 

fillstands, etc.
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(2) Impervious lining system for dikes, containment areas, and catch 

basins.

(3) When required to meet federal, state, and local regulations, refer 

to Chapter 2 of this UFC for information on design and sizing of 

oil/water separators for treatment of stormwater discharges from 

containment areas (e.g., dike areas, fillstands, equipment pads, 

etc.).
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CHAPTER 13 - FUELING FACILITY TEMPORARY DEACTIVATION

13-1 INTRODUCTION

Follow the more stringent of local, state, or applicable guidelines of this chapter during 

the initial deactivation of a fueling facility. Follow the applicable subsection when 

temporarily deactivating a fueling facility for three months or more. For continuing 

maintenance issues and reactivation of a deactivated facility, refer to inactive document

UFC 4-911-01N, which is required for these circumstances. Additional guidelines for 

the deactivation of storage tanks and pipes are provided in API Std 2610 and NFPA 30, 

Appendix C. Federal regulations addressing out-of-service underground storage tank 

systems are in 40 CFR Part 280.

13-2 GENERAL REQUIREMENTS

Chapter 2, General Design Information, contains important information on fueling 

facilities. Do not begin the design of any deactivation plan without first becoming 

completely familiar with Chapter 2 of this UFC.

13-3 FUEL STORAGE AND DISTRIBUTION FACILITIES

13-3.1 Tanks

The following items apply to deactivation of all tanks in general.

a) Empty and clean tanks in accordance with API Std 2015 and UFGS 33 

65 00, Cleaning Petroleum Storage Tanks. 

b) Provide water ballast with a copper sulphite solution (1 part copper 

sulphite to 3 million parts water) to discourage organic growth. Verify 

compatibility with environmental regulations prior to employing this 

solution.

c) Follow the procedures of MO-230 and 29 CFR Part 1910 when 

entering tanks or performing maintenance on tanks.

d) For tanks equipped with cathodic protection systems, inspect for 

proper operation and repair if necessary. For tanks not equipped with 

cathodic protection systems, investigate the economic trade-offs of 

installing those systems at deactivation versus the associated 

caretaker maintenance costs and various environmental protection 

concerns.

e) Mark each tank clearly with its status. Place a warning sign on the 

tank to indicate its current and former contents.

f) If required by state or local regulatory agencies, submit required 

documentation for “out-of-service” storage tanks.
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13-3.1.1 Aboveground Tanks

a) Empty and evaluate for hazardous atmosphere as defined by 29 CFR 

Part 1910.146. 

b) Wash and dry tank interior until visibly clean in accordance with API 

Std 2015. 

c) Physically disconnect all fuel connections.

d) Treat the interiors of tanks that have been used to store fuel oil with a 

corrosion-preventive compound. For all other steel tanks, coat the 

unpainted interior surfaces with a preservative lubricating oil.

e) Close vents on lubricating oil tanks. Vents on other tanks should 

remain open. 

f) Partially fill tanks subjected to high winds to prevent overturning. Use 

water except where there is the possibility of it freezing and rupturing 

the tanks. In those environments, use kerosene. Add caustic soda to 

the water to obtain a pH of 10 or a corrosion inhibitor. Determine the 

amount of liquid ballast required based on the expected winds, size of 

the tank, and specific gravity of the liquid used.

g) Comply with API Std 2015. 

h) Comply with state and local environmental requirements.

13-3.1.2 Underground Tanks

a) Empty, evaluate for hazardous atmosphere as defined by 29 CFR Part 

1910.146, and clean underground metal and concrete tanks.

b) Partially fill tanks insufficiently anchored against flotation with water to 

prevent buoyancy. Provide adequate safeguards where there is 

danger of the water freezing.

c) Provide a minimum of 12 inches (300 mm) of water in rubber-lined 

concrete tanks.

d) Leave vent lines on underground tanks open and make sure the vents 

are adequately screened.

e) Tightly cap or plug all other tank openings after removal of equipment.

f) Provide release detection where fuel is left in the tank.

g) Comply with 40 CFR Part 280 and any applicable state and local 

environmental regulations.
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13-3.1.3 Tank Level Controls

a) Remove controls such as float control valves, float-operated gauges, 

low level cutoffs, water detector locks, and probes from tanks.

b) Clean, treat with corrosion-preventive compound, and store controls in 

a dry place.

13-3.2 Pipelines

a) Drain and vacuum extract all fuel from the pipeline.

b) If possible, pig the pipeline to remove any residual fuels.

c) Blind all flange connections and vents.

d) Charge the line with nitrogen gas.

e) Continue to provide cathodic protection and maintain the nitrogen 

charge.

f) Externally coat unpainted and unwrapped lines exposed to the weather 

with a corrosion-preventive compound.

13-3.2.1 Pipeline Equipment

a) Remove, clean, coat inside and outside with a light oil, and reinstall 

strainers.

b) Remove, clean, treat with corrosion-preventive compound, and store 

meters in a dry place.

c) Keep gaskets tight to prevent dirt and water from entering.

d) Remove, clean, grease, and store hydraulically operated diaphragm 

control valves in a dry place.

e) Paint exterior or treat with a corrosion-preventive compound and leave 

all other valves, such as plug valves and check valves in place.

f) Lubricate plug valves and leave in an open position.

g) Remove, tag, date, and store hoses in dry storage.

13-3.2.2 Fueling Pits

a) Inspect, tag, and secure fueling pits. 

b) Make provisions for pumping pits dry.
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13-4 FACILITIES

13-4.1 General Considerations

a) Make arrangements to retain the minimum amount of maintenance 

equipment. 

b) Check and label all keys to all doors, gates, hatches, and other moving 

items.

c) Clean and repair as necessary all storm sewers, drainage ditches, and 

other drainage structures to prevent flooding and storm damage to 

roads, runways, tracks, and structures.

13-4.2 Fencing

a) Tighten connections at gates, posts, braces, guys, and anchorages to 

ensure stability and correct alignment.

b) Clean and lubricate all hinges, latches, locking devices, and all other 

alignment hardware.

c) Confine painting to those parts of fences and gates that show signs of 

corrosion. 

13-4.3 Paved Surfaces

a) Unpaved shoulders

(1) Provide unpaved shoulders with only the repairs necessary to 

ensure positive drainage of surface water from the adjoining 

pavement.

(2) Fill holes and ruts and blade ridges to eliminate standing water. 

(3) Backfill depressions when the undermining of pavement is 

threatened.

(4) When possible, retain existing ground cover.

b) Concrete pavements

(1) Repair concrete pavements only as required to perform service 

activities and to prevent severe disintegration.

(2) Patch bituminous surfaces of depressed or broken slabs to 

prevent ponding of water and the resultant saturation of the 

subgrade.
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(3) Seal joints and cracks in concrete pavement with bituminous 

material.

c) Bituminous pavements

(1) Limit surface repairs of bituminous pavements to the repair of 

holes, raveled areas, edge failures, and open cracks.

(2) Repair unused surfaces only as necessary to maintain drainage 

and to prevent the ponding of surface water.
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CHAPTER 14 - FUELING FACILITY CLOSURE

14-1 CLOSURE REQUIREMENTS

Follow the more stringent of local, state, or applicable guidelines in this chapter when 

permanently closing a fuel facility or a portion of a fuel facility. Additional guidance on 

closure and disposal of storage tanks is available in Appendix C of NFPA 30 and API 

Std 2610.

14-1.1 Aboveground Tanks

a) Physically disconnect all fuel connections.

b) Remove fuel.

c) Clean tank in accordance with API Std 2015. 

d) Dismantle the tank and dispose of as scrap steel.

e) Comply with API Publ 2202. 

f) Comply with state and local environmental requirements.

14-1.2 Underground Tanks

a) Perform a soil and groundwater analysis to determine if a fuel release 

occurred.

b) Review and comply with 40 CFR Part 280 and any applicable state 

and local environmental regulations.

c) If allowed by federal, state and local regulations, perform closure in 

place, as outlined in API RP 1604. However, this alternative may be 

more expensive than removal for small volume tanks. Abandoning in 

place also impedes soil clean-up and future land use.

d) If removal is required, excavate and dispose of the tank in accordance 

with API RP 1604. 

e) Comply with applicable guide specifications and EM 1110-1-4006. 

14-1.3 Pipelines

a) Physically disconnect the pipeline from any active fuel systems.

b) Remove all fuel and pig to remove any residual fuel.
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c) Purge the pipeline to remove all vapors. Do not use water as flushing 

media because it will typically generate large quantities of hazardous 

waste with high disposal costs. 

d) Excavate the line only if required by federal, state, or local regulations 

or if deemed necessary by Service Headquarters for land reuse.

e) Report any contaminated soil or groundwater discovered during 

excavation to the appropriate state and local environmental authorities.

f) If excavation is not performed, fill the pipeline with cellular concrete or 

other acceptable inert solid material allowed by regulations requiring 

the filling. Consider the lowest cost from the acceptable materials list. 

As an option, the pipeline can be capped, where it meets 

environmental regulations and with approval from Service 

Headquarters. 

14-2 GENERAL REQUIREMENTS

Chapter 2, General Design Information, contains important information on fueling 

facilities. Do not begin the design or modification of any closure plan without first 

becoming completely familiar with Chapter 2 of this UFC.

14-3 INVENTORY

Prepare an inventory of valuable fueling hardware which could be easily salvaged and 

reused at another base. Equipment such as pantographs, control valves, pumps, and 

filtration equipment are always in demand. Submit list to your command fuels engineer.
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Plate 001 – UFC Chapter Identification Plan
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Plate 002 – Tank Truck and Tank Car Receiving and Dispensing Facilities
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Plate 003 – Tank Truck and Tank Car Off-Loading Drop Tank System
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Plate 004 – Tank Truck and Tank Car Packaged Off-Loading System
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Plate 005 – Tank Truck and Tank Car Loading System and Direct Off-Loading System
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Plate 006 – Refueler Truck Facilities Layout Plan
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Plate 007 – Refueler Truck Loading Systems
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Plate 008 – Aircraft Direct Fueling Systems Large Frame Aircraft On-Apron Fueling 

Positions
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Plate 009 – Aircraft Direct Fueling Systems Small Frame Aircraft Fueling Lane and 

Apron Edge
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Plate 010 – Aircraft Direct Fueling Systems Small Frame Aircraft In-Shelter Fueling 

Positions
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Plate 011 – GOV Vehicle Motive Fuel Filling Station Plan
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Plate 012 – Tactical Refueler Ground Product Truck Loading Facility Plan
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Plate 013 – Tactical Refueler Ground Product Truck Loading Systems
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Plate 014 – Level Alarm Setpoints Vertical Aboveground Tank with Floating Pan
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Plate 015 – Level Alarm Setpoints Vertical Aboveground Tank without Floating Pan

 
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Plate 016 – Aboveground Vertical Storage Tanks Inlet Fill Connection
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Plate 017 – Horizontal Underground Storage Tanks Inlet Fill Connection
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Plate 018 – Horizontal Aboveground Storage Tanks Inlet Fill Connection
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Plate 019 – Earthen Dikes
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Plate 020 – Piping Systems Sliding Pipe Support
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Plate 021 – Piping Systems Anchor Pipe Support
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Plate 022 – Aviation System Piping Materials System Standards
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Plate 023 – Thermal Relief Piping Systems Integral Valve and Conventional
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Plate 024 – Thermal Relief Piping Systems Equipment Pump House or Pads
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Plate 025 – Thermal Relief Piping Systems Tank Truck and Refueler Racks
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Plate 026 – Thermal Relief Piping Systems Storage Tanks
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Plate 027 – Liquefied Petroleum Gas Facilities Small Volume Facility for Trucks and

Cylinders
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Plate 028 – Liquefied Petroleum Gas Facilities Large Volume Facility for Tank Cars 

and Water Vessels
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Plate 029 – Liquefied Petroleum Gas Facilities Tank Spacing Requirements
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Plate 030 – Liquefied Petroleum Gas FacilitiesTank Spacing Requirements
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GLOSSARY

ABBREVIATIONS AND ACRONYMS

ACGIH. American Conference of Governmental Industrial Hygienists.

AEI. Architectural and Engineering Instruction.

AFFF. Aqueous film-forming foam.

AFPET. Air Force Petroleum Office. 

AFSS. Automated fuel service station.

AIS. Automated Information System.

ANSI. American National Standards Institute.

APC. Army Petroleum Center. 

API. American Petroleum Institute.

ASCII. American Standard Code for Information Interchange.

ASME. American Society of Mechanical Engineers.

AST. Aboveground Storage Tank.

ASTM. American Society for Testing and Materials.

ATG. Automatic tank gauging.

BOCA. Building Officials and Code Administrators International, Inc.

BSM-E. Business System Modernization – Energy. 

BS&W. Common abbreviation for bottom sediment and water as found in the bottom of 

fuel tanks, also; a type of sampling procedure.

Btu. British thermal unit.

CFR. Code of Federal Regulations.

CI. Corrosion inhibitor.

CNG. Compressed Natural Gas.

C02. Chemical notation for carbon dioxide; fire extinguishing agent.
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CONUS. Continental United States.

COTS. Commercial-off-the-shelf.

DBB. Double block and bleed.

DESC. Defense Energy Support Center.

DFM. Diesel fuel marine.

DIEGME. Diethylene glycol monomethyl ether.

DLA. Defense Logistics Agency.

DoD. Department of Defense.

DOT. Department of Transportation.

EFSO. Emergency fuel shut-off.

EMAT. Electromagnetic acoustic transducer.

EPDM. Ethylene-propylene terpolymer.

EPU. Emergency power unit.

F-A. Fire Resistent Aboveground Storage Tank.

FDV. Fuel Delivery Vehicle. 

FRP. Fiberglass reinforced plastic.

FSII. Fuel system icing inhibitor.

H-A. Horizontal Aboveground Storage Tank. 

HDPE. High-density polyethylene.

HTH. Calcium hypochlorite.

H-U. Horizontal Underground Storage Tank. 

ICBO. International Conference of Building Officials.

ICC. International Code Council. 
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JPTS. Jet Propellant Thermally Stable. 

LPG. Abbreviation for liquefied petroleum gas; propane, butane.

MAJCOM. Major Command. A major subdivision of the Air Force, directly subordinate 

to Headquarters US Air Force.

MFL. Magnetic flux leakage.

MIL. A unit of length equal to one thousandth of an inch, especially used to measure 

the thickness of paints and coatings.

Mogas. Common contraction of motor gasoline, referring to fuel for land vehicles.

NACE. National Association of Corrosion Engineers.

NATO. North Atlantic Treaty Organization.

NAVAIR. Naval Air Systems Command. 

NBBI. National Board of Boiler and Pressure Vessel Inspectors.

NBIC. National Board Inspection Code.

NFESC-OCD. Naval Facilities Engineering Service Center, Ocean Construction 

Division.

NFPA. Abbreviation for the National Fire Protection Association.

NOLSC-P. Naval Operational Logistics Support Center Petroleum. 

NPDES. National Pollutant Discharge Elimination System.

OCONUS. Outside of the Continental United States. 

OMSI. Operation and maintenance support information.

OSHA. Occupational Safety and Health Act of 1970.

P-A. Protected Aboveground Storage Tank.

PACAF. Pacific Air Force.

PDP. Pressure dew point.

pH. A number assigned to indicate whether a substance is acidic or alkaline (pH 7 is 

considered neutral, less than 7 is acidic and more than 7 is alkaline).
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PLC. Programmable logic controller.

POL. A commonly used abbreviation which broadly refers to all petroleum, oils, and 

lubricants.

PSI or PSIG. Abbreviation for pounds per square inch, the unit of pressure 

measurement; gage pressure above atmospheric.

PSIA. Pounds per square inch absolute; pressure above an absolute vacuum.

PVC. Polyvinyl chloride.

RDBMS. Relational Database Management System.

SAE. Abbreviation for Society of Automotive Engineers, used in conjunction with 

specification for viscosity of lubricating oils.

SPCC. Spill prevention control and countermeasure.

SPR. Single Point Receptacle. 

SSPC. Steel Structures Painting Council.

STANAG. Standardization Agreement (NATO term)

TAU. Twin agent unit.

TYCOM. Type Command (Navy/Marine Corps equivalent of MAJCOM). 

UFGS. Unified Facilities Guide Specifications.

ULSD. Ultra Low Sulfur Diesel.

UPV. Unfired pressure vessel.

UST. Underground Storage Tank.

USAFE. United States Air Forces in Europe.

V-A. Vertical Aboveground Storage Tank.

VOC. Volatile organic compound.

V-U. Vertical Underground Storage Tank.
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TERMS

Additive. Chemical added in minor proportions to fuels or lubricants to create, enhance 

or inhibit selected properties; example, fuel system icing inhibitor (FSII).

Aircraft Direct Fueling System. Method used to refuel aircraft by issuing fuel directly to 

the aircraft from the tank farm without first transferring the fuel to a refueler truck. Also

known as a hydrant system. 

Aircraft Refueling Adapter. A device, mounted on an aircraft, that combines with a 

pressure refueling nozzle mounted on a refueling vehicle or station to form a quick 

disconnect connection for the purpose of refueling or defueling aircraft. It can also be 

used for refueling and defueling refuelers. 

Ambient. Encompassing on all sides, as temperature.

Anode. The positively charged electrode of an electrolytic cell.

API Gravity. Petroleum industry scale for measuring the density of oils.

Aromatic Hydrocarbons. Characterized by the presence of the hexagonal benzene ring; 

also having an aroma.

Atmospheric Pressure. The pressure exerted by the earth's atmosphere, when 

measured at sea level under standard conditions is equal to 14.7 pounds per square 

inch (101 kPa).

Atmospheric Tank. Storage tank which operates at or near atmospheric pressure (14.7 

psi (101 kPa) at sea level).

Auto-ignition Temperature. The temperature at which a substance will ignite without the 

further addition of energy from an outside source.

Ballast Water. Water carried in ship's fuel tanks or cargo tanks to improve the vessel's 

stability when empty of petroleum.

Barrel. Measure of volume as used in the petroleum industry, equivalent of 42 U.S. 

gallons (0.16 m3

).

Blind Flange. Piping flange with no passage through the center.

Boiler Fuel Oil. Fuel oil that is burned in furnaces to create steam or hot water, also 

called fuel oil.

Boiling Point. The temperature at which the vapor pressure of a liquid is equal to the 

pressure of the vapor above the liquid, usually atmospheric pressure. The temperature 
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increases as the atmospheric pressure increases.

Bollard. A heavy solid post used to protect equipment from an impact. Also used on 

docks and ships for mooring.

Bond. Electrical connection between two objects which equalizes their potential.

Boom. Flexible floating barrier consisting of linked segments designed to contain free 

oil on the surface of a body of water.

Booster Pump. Pump installed along the run of a long pipeline for the purpose of 

increasing pressure.

Bottom Loading. Method of filling tank trucks or tank cars through a tight connection at 

the bottom.

Breakaway Coupling. Coupling designed to part easily with a moderate pull with a drybreak from both directions.

Breathing. The movement of vapors into or out of a container because of natural 

cyclical heating and cooling.

Bulk Storage Tank. Storage tank for fuel normally received by pipeline, tank truck, or 

tank car. For aviation turbine fuel, configure tank to supply fuel to operating storage 

tanks, either directly tank-to-tank, or indirectly by issuing fuel to tank trucks, tank cars,

barges, ships, or pipelines. 

Bunkers. Common expression referring to heavy residual boiler fuel.

Calibration. Adjustment of the scale of a graduated device to meet an established 

standard, especially applicable to the adjustment of meter registers to indicate true 

volume as determined by a standard measure.

Catalyst. A substance that provokes or accelerates chemical reactions without itself 

being altered.

Cathodic Protection. A method for preventing the corrosion of metals by electrolysis.

Centistokes. A centistoke (cSt) is equal to 1 millimeter squared per second.

Centrifugal Pump. A rotating device which moves liquids and develops liquid pressure 

by imparting centrifugal force.

Centrifugal Separator. A rotating device which separates liquids of different density by 

centrifugal force, a form of centrifuge.

Clarifier. Commonly used name for a micronic filter.
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Clean Product. Refined light petroleum products such as gasoline or distillates, as 

differentiated from residuals or black oils.

Clear and Bright. Description of uncontaminated fuel indicating a complete absence of 

haze, free water or particulate matter.

Cloud Point. The temperature at which a fuel develops a cloudy or hazy appearance 

due to the precipitation of or moisture. The condition developed is called temperature 

haze.

Coalescer. A porous substance through which a liquid is passed to remove unwanted 

water from fuel by causing very small drops of water to form larger drops (coalesce) 

which will separate from fuel by gravity. 

Coalescer Vessel. A pre-filtration vessel designed to remove gross amounts of water 

and, to a lesser degree, particulate water. Types include haypack coalescers. 

Combustible Liquid. Any liquid having a flash point at or above 100 °F (38 °C).

Combustible Vapor Indicator. Device which measures the quantity of combustible vapor 

in the atmosphere; explosion meter.

Contaminated Fuel. Petroleum fuel containing suspended or emulsified water, cleaning 

chemicals; or other foreign matter such as iron scale, dust, or other solid particles; or 

containing an unacceptable percentage of noncompatible fuel or other liquids; or 

containing more than one, or all of these classes of contaminants.

Contamination. The accidental addition to a petroleum fuel of some foreign material 

(contaminant) such as dirt, rust, water, or accidental mixing with another grade of 

petroleum.

Copper-copper Sulphate Electrode. Reference electrode used to measure structure-tosoil potentials for corrosion control; a half cell.

Corrosion. The process of dissolving, especially of metals due to exposure to 

electrolytes.

Crude Oil. Petroleum in its natural state prior to refining.

Cut and Cover. Refers to underground vertical storage tanks.

Cyclonic Filter. A filter used to remove gross amount of particulate matter using the 

principle of centrifugal force to separate solid particles from a liquid. 

Deadman Control. A control device, such as a switch or valve, designed to interrupt 

flow if the operator leaves his station.
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Defueler. Tank vehicle used to remove fuel from aircraft.

Density. The mass per unit volume of a substance.

Dike. An embankment or wall, usually of earth or concrete, surrounding a storage tank 

to impound the contents in case of a spill.

Dissolved Water. Water which is in solution with fuel as opposed to in suspension.

Distillate. Common term for any of a number of fuels obtained directly from distillation 

of crude petroleum, usually includes kerosene, JP-5, light diesel, and light burner fuels.

Double Block and Bleed Valve. A valve with two seats with a cavity in between them 

which can be drained while the valve is closed to prove the valve is not leaking.

Downgrade. To use a fuel for a lesser purpose than originally specified, often because 

of contamination.

Effluent. Stream flowing; discharge.

Electrode. Electrical conductor through which an electric current enters or leaves an 

electrolyte.

Electrolysis. Chemical change, especially decomposition, produced in an electrolyte by 

an electric current.

Electrolyte. A substance capable of forming solutions with other substances which 

produce ions and thereby permit the flow of electric currents.

Electrical Conductor. A substance which permits the flow of electric currents without 

permanent physical or chemical change; copper, aluminum.

Element. Term used to describe the ‘disposable’ part of a filter vessel such as a 

filter/separator, micronic filter, or haypack coalescer. Also referred to as a cartridge.

Emulsion. A suspension of small globules of one liquid in a second liquid with which the 

first will not mix.

Epoxy Coating. A coating of thermosetting resins having strong adhesion to the parent 

structure, toughness, and high corrosion and chemical resistance, also used as an 

adhesive.

Explosive Limits - (Upper and Lower). Limits of percentage composition of mixtures of 

combustible vapors and air which are capable of producing an explosion or combustion 

when ignited; also flammable limit.
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Explosion-proof. Classification of electrical enclosures for use in hazardous areas

designed to prevent the passage of internal arcs, sparks or flames.

Fender. Part of a pier structure designed to absorb the impact of a moving vessel.

Fiberglass. Composite material consisting of glass fibers in a matrix of resin such as 

epoxy.

Filling Station. A facility designed to fill vehicles with gasoline or diesel as motive fuel. 

Filter. A porous substance through which a liquid is passed to remove unwanted 

particles of solid matter. Types include cyclonic filters and micronic filters. 

Filter/Coalescer Elements. A type of coalescer that removes water and particulate 

matter from fuel. Used as the first element in filter/separators. Also referred to as 

coalescer elements or coalescers. 

Filter/separator. A filtration vessel consisting of two separate element types (also called 

stages). The first stage consists of filter/coalescer elements to remove fine particulate 

matter and to remove entrained water by coalescing it; the second stage consists of 

separator elements to prevent fine droplets of water (caused by the coalescing process) 

from reaching the vessel outlet. It removes dirt and free water down to the very low 

levels required for aircraft operations. Filter/separators are the only approved vessels 

for use in fine filtration; they are occasionally used for pre-filtration as well. 

Fine Filtration. A term used to refer to filtration vessels used to remove dirt and free 

water down to the very low levels required for aircraft operations. Fine filtration vessels 

are always filter/separators. 

Fire Resistant Tank. Aboveground storage tank that is listed in accordance with UL 

2080, that consists of a primary tank that is protected or insulated from a 2-hour fire 

exposure.

Flammable Liquid. Any liquid having a flash point below 100 degrees F (38 degrees C) 

and a vapor pressure not exceeding 40 psia (275 kPa) at 100 degrees F (38 degrees 

C).

Flash Point. The lowest temperature at which a combustible or flammable liquid 

produces enough vapor to support combustion.

Floating Roof Tank. Petroleum storage tank with a roof that floats on the liquid surface 

and rises and falls with the liquid level.

Flocculation. A treatment process in which waste waters are clarified by the addition of 

chemical coagulants to produce finely divided precipitates which will agglomerate into 

larger particles.
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Free Water. Undissolved water content in fuel.

Freeze Point. The temperature at which wax crystals form in distillate fuels and aviation 

turbine fuels.

Fuel Oil. See Boiler Fuel Oil. 

Fuel Quality Monitor. A special type of filter designed to interrupt the flow of fuel when 

dirt or water content becomes too great.

Galvanizing. Rust resistant zinc coating applied to iron and steel.

Ground. An electrical connection to earth.

Haypack Coalescer. A type of coalescer that uses hay, straw, or excelsior as a medium 

to remove large slugs of water.

Hazardous Area. Electrical classification for areas where flammable or combustible 

liquids or vapors may be present.

Hot Refueling. Refueling of aircraft when one or more engines are running. 

Housekeeping Pad. Concrete pad usually installed on concrete slabs or floors to 

elevate and anchor equipment. Housekeeping pads aid in maintenance and keep 

equipment clear of debris.

Hydrant System. Distribution and dispensing system for aviation turbine fuels 

consisting of a series of fixed flush type outlets or hydrants connected by piping. It 

issues fuel directly to the aircraft from the tank farm without first transferring the fuel to a 

refueler truck. Also known as an aircraft direct fueling system. 

Hydrocarbon. A compound made up exclusively of hydrogen and carbon in various 

ratios and molecular arrangements.

Hydrostatic Head. Pressure caused by a column of liquid.

Hydrostatic Test. A test for leaks in a piping system using liquid under pressure as the 

test medium.

Hydrostatic Test Pressure. The pressure in the system while it is undergoing a 

hydrostatic leak test as defined by ANSI/ASME B31.3. For the purpose of this 

document, set at 1.5 times the maximum allowable design pressure.

Ignition Temperature. The minimum temperature required to initiate or cause selfsustained combustion independent of any heating or heated element.

Intrastate Interterminal Pipelines. Interterminal pipelines that do not cross state lines.
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Interstate Interterminal Pipelines. Interterminal pipelines that cross state lines.

Impervious. Not easily penetrated. The property of a material that does not allow, or 

allows only with great difficulty, the movement or passage of a fluid. Also referred to as 

impermeable.

Impressed Current System. A cathodic protection system using an outside source of 

electric power.

Inert Material. Any solid, liquid, or gaseous substance not combustible or fire-producing 

when exposed to the atmosphere under ordinary climatic conditions; it includes 

common metals, packing materials, ceramic materials, construction materials such as 

concrete, mineral aggregates, and masonry.

Installation Pipelines. Pipelines which connect POL facilities within an installation such 

as a barge pier to a bulk facility and a bulk facility to an operating (ready-issue) tank. 

These pipelines do not cross property lines and, therefore, do not leave the government 

facility and control.

Interterminal Pipelines. Pipelines which connect two government installations such as a 

Defense Energy Supply Center depot to a military installation. These pipelines cross 

property lines and cross public and/or private properties, streets, highways, railroads, 

and utility rights-of-way.

JP Fuel. Military designation applied to aviation turbine fuels (e.g., JP-4, JP-5, and JP8).

Kerosene. A general term covering the class of refined petroleum which boils between 

370 degrees F and 515 degrees F (188 degrees C and 268 degrees C). Mostly used in 

oil lamps and cooking stoves.

Kerosene Type Aviation Turbine Fuel. JP fuel derived from kerosene without the 

addition of naphtha; characterized by a flash point of 100 degrees F (38 degrees C) or 

more.

Kinematic Viscosity. The ratio of viscosity of a liquid to its specific gravity at the 

temperature at which the viscosity is measured.

Lead Hazard. Poisonous contamination of the atmosphere, sludge, or other 

surroundings, particularly in petroleum storage tanks,-caused by tetraethyl lead or its 

residues.

Line Blind. A solid flat plate used to obtain absolute shut-off of flow. Also, referred to as 

spectacle plates or flanges, blinding plate, figure eights and paddle blinds.

Liter (L). Equivalent to 0.001 m3. 
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Lube Oil. Common contraction for lubrication oil; used to reduce friction and cool 

machinery.

Maximum Allowable Design Pressure. The maximum allowable pressure of a fuel 

system or component will see. For the purposes of this document, set at the pressure 

rating of a flanged joint per ANSI/ASME B16.5. 

Maximum Allowable Operating Pressure. The maximum pressure at which a system is 

to operate. For the purposes of this document set at 2/3 of the hydrostatic test pressure, 

not to exceed the maximum allowable design pressure.. 

Maximum Allowable Surge Pressure. The maximum pressure allowed during a surge 

event. For the purposes of this document, set the pressure at 133% of the qualified 

Maximum Allowable Operating Pressure.

Micron. A unit of length equal to one millionth of a meter, especially used as a measure 

of the size of very fine particles found as contaminants in fuel.

Micronic Filter. A type of pre-filter vessel equipped with paper filter elements, designed 

to remove particulate matter from a fuel stream. Will not remove water.

Military Specifications. Guides for determining the quality requirements for materials 

and equipment used by the military services (MIL).

Motive Fuel. Any fuel that is used to power vehicles, aircraft, or vessels.

Naphthas. Refined petroleum which boils at 800 degrees F (427 degrees C) to 4400 

degrees F (2427 degrees C), used as a component of gasoline and solvents.

Nipple. Short length of pipe, usually used to make side branch connections.

Nondestructive Testing. A method of inspecting materials without cutting, drilling or 

otherwise destroying the material; usually used to examine steel plates, pipes, and 

welds.

Nozzle. A spout or connection, usually with a control valve through which fuel is 

discharged into a receiving container.

Octane Number. A numerical measure of the antiknock properties of automotive 

gasoline as measured against standard reference fuels, under controlled laboratory 

conditions. Iso-octane is a reference fuel whose octane number is given a value of 100.

Off-Specification. Usually referring to fuel which is contaminated or otherwise deficient 

in quality. Commonly used contraction for off-specification is “off-spec”. 

Oil/water Separator. A device used to separate mixtures of oil and water, usually by the 
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difference in specific gravity and usually to protect the environment from contamination 

by the oil.

Oily-water Mixture. Mixture in which water comprises more than half the total volume. 

Most such untreated mixtures contain less than 15 percent oil, some of which may be in 

emulsified form.

Operating Storage Tanks. Storage tank for aviation turbine fuel configured to issue fuel 

directly to an aircraft, hydrant system, or refueler. A tank configured to issue aviation 

turbine fuel to a refueler only in an emergency is considered a bulk storage tank. 

Orifice Plate. A plate with a hole in the center held between two flanges in a pipeline, 

used to create a drop in pressure which is proportional to flow and can be used to 

measure the flow or to modulate control devices.

Pantograph. A series of pipes, joined by flexible joints, used to connect fueling 

equipment to aircraft.

Parallel Pumps. Two or more pumps having common suction and discharge connections.

Particulate Matter. Solid particles such as dirt, grit, and rust, which contaminate fuel.

Pigging. The use of internal pipe tools, called pigs, to clean the inside of the pipe, 

determine the geometry of the pipe, and determine the location and magnitude of any 

internal or external corrosion occurring on the pipe.

Pig Launcher. An arrangement of valves and closure devices to launch pigs at the 

beginning of their run through a pipeline.

Pig Receiver. An arrangement of valves and closure devices to trap pigs at the end of 

their run through a pipeline.

Pile Cluster. A group of pilings driven close together and usually wrapped with wire 

rope to act as fender or mooring for small vessels.

Pour Point. The lowest temperature at which an oil will pour or flow without disturbance.

Pontoon Roof. A type of floating roof for a storage tank having liquid-tight 

compartments for positive buoyancy.

Pre-filter. A term used to refer to any filtration vessel used immediately upstream of a 

fine filtration filter/separator in a fuel storage/delivery system. They are used to remove 

gross amounts of particulates and/or free water from a fuel stream in order to prolong 

the life of the elements used in the fine filtration filter/separator. Typically cyclonic or 

micronic filters are used as pre-filters although haypack coalescers or even 

filter/separators may also be used in this role. 
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Pre-Filtration. Pre-filters or coalescers vessels placed ahead of additional, more 

sophisticated, fine filtration vessels for the gross removal of solids and/or free water. 

Pressure Drop. The loss in pressure of a liquid flowing through a piping system caused 

by friction of pipe and fittings, velocity, and change in elevation.

Pressure Refueling Nozzle. A device, mounted on a refueling vehicle or station, that 

combines with an aircraft refueling adapter mounted on an aircraft to form a quick 

disconnect connection for the purpose of refueling or defueling aircraft. It can also be 

used for refueling and defueling refuelers. 

Product Recovery Tank. Tank used to collect and store aviation turbine fuel that would 

otherwise become waste fuel. It is part of a closed system that, either manually or 

automatically, pumps the fuel back into the system through a hard piped connection. 

Tanks that do not have this hard piped connection are not product recovery tanks.

Protected Tank. Aboveground storage tank that is listed in accordance with UL 2085, 

that consists of a primary tank that is protected or insulated from a 2-hour fire exposure 

and protected from physical damage.

Radiograph. An image produced on radiosensitive film by invisible radiation such as Xray, specifically the image produced by radiographic inspection of welds and plates.

Ready-Issue Tank. See operating storage tank. 

Recoverable Fuel. That portion of the fuel which may be separated and collected from 

a given lot of contaminated fuel, by proper processing in the treating facility in question.

Recovered Oil. Used to denote untreated petroleum fuel removed from oil-water 

separators or picked up after being spilled on land or water. Also used to mean oil 

which has been separated from and collected from a given lot of contaminated fuel by 

processing in a treating facility.

Refueler. Except for tactical refuelers, tank truck vehicles used to resupply aircraft with 

fuel. Tactical refuelers may transport ground products (gasoline, diesel) or aviation 

turbine fuel.

Reid Vapor Pressure. Vapor pressure measured under controlled conditions with the 

liquid temperatures at 100 °F (38 °C).

Residual Fuel Oil. Topped crude petroleum from refinery operations. Commercial 

grades of Burner Fuel No. 5, No. 6, and bunker fuels are residual fuel oils.

Relaxation Tank. Small tank in a fuel dispensing piping system downstream of 

filter/separators designed to remove static electricity from the liquid stream before 

discharge into a receiving tank.
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Rotary Pump. A positive displacement pump which operates in rotary fashion such as a 

vane, gear, bucket, lobe, or screw pump; not centrifugal, turbine, or propeller pumps.

Rust. Ferric oxide, a reddish-brown scaly or powdery deposit found on the surface of 

steel and iron as a result of oxidation of the iron.

Safety Relief Valves. Valves that are installed on pressurized vessels to relieve 

pressure in access of the maximum allowable working pressure of the vessel. Safety 

valves are provided to protect people, equipment, and property.

Scraper. A type of cleaning pig used in pipelines.

Secondary Containment-Type Tank. A tank that has an inner and outer wall with an 

interstitial space (annulus) between the walls and that has a means for monitoring the 

interstitial space for a leak.

Service Headquarters. Defined as follows: Army – Headquarters, U.S. Army Corps of 

Engineers Technical POC, POL Facility Criteria (CECW-CE); Air Force - The Air Force 

Fuels Engineer (HQ AFCESA/CEOA) through the applicable Major Command 

(MAJCOM) Fuels Engineer; Navy/Marine Corps: NAVFAC POL Facility Subject Matter 

Expert (NFESC-OP232); Defense Energy Support Center (DESC) - DESC Facilities 

Engineer. Defense Energy Support Center (DESC-WI) 

Single Point Receptacle. Point at which fueling hose is attached to skin of aircraft 

during aircraft refueling operations.

Skimmer. A device used to collect thin layers of oil floating on a body of water.

Slop Oil. Oil or fuel which has become contaminated with other oils or substances, 

often requiring separation or treatment before it is fit for use.

Sludge. Heavy viscous oily mass found in the bottom of storage tanks and treatment 

vessels, often contains rust, scale, dirt, lead additives, wax, gum, or asphalt.

Specific Gravity. The ratio of the weight in air of a given volume of a substance to the 

weight in air of an equal volume of distilled water (62.4 lb/ft3 ) (1000 kg/m3), both taken 

at the same temperature, usually 60 °F (16 °C).

Static Electricity. Accumulation of electric charge on an insulated body; also the 

electrical discharge resulting from such accumulation.

Strapping. The process of determining the volume of a storage tank or cargo hold by 

measuring its linear dimensions.

Stripper Pump. A pump used to strip or remove the last bit of liquid from a tank or pipe.

Sump. A low area or depression which receives drainage.
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Surge. Sudden increase in fluid pressure caused by sudden stopping of a moving 

stream as by a quick closing valve; hydraulic shock; also the sudden, brief increase in 

voltage or current in an electrical circuit.

Surge Arrestor. A protective device for limiting surge voltages by discharging or 

bypassing surge current, and it also prevents continued flow of follow current while 

remaining capable of repeating these functions. Designed primarily for connection

between a conductor of an electrical system and ground to limit the magnitude of 

transient (surge) overvoltages on equipment. Also known as arrestor or arrester, surge 

arrester, lightning arrestor or arrester.

Surge Suppressor. Device designed to control or reduce surges; hydraulic shock 

absorber.

Thermal Relief Valves. Valves that are installed around isolation valves to relieve 

excessive pressure caused by thermal expansion of the fuel in the pipe.

Tolerance. An allowable variation from a specified standard of measurement, 

commonly applied to the accuracy of meters.

Top Loading. Method of filling tank cars and trucks through an opening in the top.

True Vapor Pressure. Vapor pressure measured at actual liquid temperature.

Vapor Lock. Malfunction of an engine fuel system or of a pumping system caused by 

vaporization of the fuel, usually associated with gasoline.

Vapor Pressure. Internal pressure of vapor in a liquid usually in pounds per square 

inch; an indication of volatility. 

Viscosity. Measure of the internal resistance of a fluid to flow or movement, most 

commonly measured in centistokes.

Volatility. Measure of the tendency of a liquid to vaporize; vapor pressure.

Waste Oil. Oil from which the water and other contaminants cannot be removed by the 

available treating facilities, and hence is unfit for further use. This term is also loosely 

used for contaminated oil which may contain recoverable fuel collected at facilities 

having no treatment facility for fuel reclamation.

Water Bottom. Free water which has settled to the bottom of a storage tank.

Water Drawoff. A valve or similar device used to remove water from the bottom

of a tank.

Water Slug Shutoff. A valve in the discharge piping from a filter/separator which closes 
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automatically when the water in the unit rises above a set level.

Wax. Viscous or solid high molecular weight hydrocarbon substance; paraffin.

Weatherproof. Type of enclosure for electrical apparatus for outdoor service in 

nonhazardous areas.

Wharf. A landing place where vessels tie up to load or unload; pier.
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A-1 

APPENDIX A - REFERENCES

NOTE: THE FOLLOWING REFERENCED DOCUMENTS FORM A PART OF THIS 

UFC TO THE EXTENT SPECIFIED HEREIN. USERS OF THIS DOCUMENT SHOULD 

REFER TO THE LATEST REVISIONS OF CITED DOCUMENTS UNLESS 

OTHERWISE DIRECTED.

FEDERAL/MILITARY SPECIFICATIONS, STANDARDS, BULLETINS, HANDBOOKS, 

USAFE/NATO STANDARD DESIGNS, AND NAVFAC GUIDE SPECIFICATIONS: 

Unless otherwise indicated, copies are available from the Standardization Document 

Order Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094. For 

account and order information, the phone number is (215) 697-6257 or DSN 442-

2179/2667. Many of the documents below are also available on the following websites:

• The Whole Building Design Guide website provided by the National Institute of 

Building Sciences at http://www.wbdg.org/ccb. 

• The Department of Defense Single Stock Point for Military Specifications, 

Standards and Related Publications at http://dodssp.daps.dla.mil/

MILITARY SPECIFICATIONS

MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 

 

MIL-DTL-16884 Fuel, Naval Distillate

MIL-DTL-25524 Turbine Fuel, Aviation, Thermally Stable (JPTS)

MIL-DTL-38219 Turbine Fuel, Low Volatility, JP-7 

MIL-DTL-83133 Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO 

F-34), NATO F-35, and JP-8+100 (NATO F-37). 

MIL-DTL-85470 Inhibitor, Icing, Fuel System, High Flash

MIL-DTL-87107 Propellant, High Density Synthetic Hydrocarbon Type, 

Grade JP-10

 

MIL-PRF-17331 Lubricating Oil, Steam Turbine and Gear, Moderate 

Service

MIL-PRF-25017 Inhibitor, Corrosion/Lubricity Improver, Fuel Soluble

MIL-PRF-26536 Propellant, Hydrazine

MIL-PRF-9000 Lubricating Oil, Shipboard Internal Combustion 
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A-2 

 Engine, High Output Diesel

DoD STANDARD DESIGNS

AW 78-24-27 Standard Fueling Systems; Aboveground Vertical 

Steel Tanks with Floating Pans and Fixed Roofs

AW 78-24-28 Pressurized Hydrant Fueling System, Type III

AW 78-24-29 Aircraft Direct Fueling System, Type IV

HANDBOOKS

MIL-HDBK-1004/6 Lightning Protection

MIL-HDBK-1005/17 Nondomestic Wastewater Control and Pretreatment 

Design Criteria 

 

MIL-HDBK-1013/1 Design Guidelines for Physical Security of Facilities

MIL-HDBK-1013/10 Design Guidelines for Security Fencing, Gates, 

Barriers, and Guard Facilities

UNIFIED FACILITIES GUIDE SPECIFICATIONS

UFGS 09 97 13.15 Epoxy/Fluoropolyurethane Interior Coating of Welded 

Steel Petroleum Fuel Tanks

UFGS 09 97 13.17 Three Coat Epoxy Interior Coating of Welded Steel 

Petroleum Fuel Tanks

UFGS 09 97 13.27 Exterior Coating of Steel Structures

UFGS 28 31 76 Interior Fire Alarm and Mass Notification System

UFGS 33 65 00 Cleaning Petroleum Storage Tanks

UFGS 44 42 53 Parallel Plate [or Vertical Tube], Gravity Oil-Water 

Separator

UNIFIED FACILITIES CRITERIA

UFC 1-200-01 General Building Requirements

UFC 2-000-05N/P-80 Facility Planning Criteria for Navy/Marine Corps 

Shore Installations
UFC 3-460-01

16 August 2010

A-3 

UFC 3-130-01 General Provisions - Arctic and Subarctic 

Construction

UFC 3-130-02 Site Selection and Development - Arctic and Subarctic 

Construction

UFC 3-130-03 Runway and Road Design - Arctic and Subarctic 

Construction

UFC 3-130-04 Foundations for Structures - Arctic and Subarctic 

Construction

UFC 3-130-05 Utilities - Arctic and Subarctic Construction

UFC 3-130-06 Calculation Methods for Determination of Depths of 

Freeze and Thaw in Soil - Arctic and Subarctic 

Construction

UFC 3-130-07 Buildings - Arctic and Subarctic Construction

UFC 3-220-01N Geotechnical Engineering Procedures for Foundation 

Design of Buildings and Structures

UFC 3-220-10N Soil Mechanics

UFC 3-240-02N Wastewater Treatment Systems Augmenting 

Handbook 

UFC 3-240-09FA Domestic Wastewater Treatment 

UFC 3-250-01FA Pavement Design for Roads, Streets, Walks, and 

Open Storage Areas

UFC 3-250-18 General Provisions and Geometric Design for Roads, 

Streets, Walks, and Open Storage Areas

FA

UFC 3-260-01 Airfield and Heliport Planning and Design

UFC 3-260-02 Pavement Design for Airfields

 

UFC 3-301-01 Structural Engineering

UFC 3-310-04 Seismic Design for Buildings

UFC 3-420-01 Plumbing Systems

UFC 3-460-03 O&M: Maintenance of Petroleum Systems
UFC 3-460-01

16 August 2010

A-4 

UFC 3-501-01 Electrical Engineering

UFC 3-550-01 Exterior Electrical Power Distribution

UFC 3-570-02N Electrical Engineering Cathodic Protection

UFC 3-580-01 Telecommunications Building Cabling Systems 

Planning and Design

UFC 3-600-01 Fire Protection Engineering for Facilities

UFC 4-010-01 DoD Minimum Antiterrorism Standards for Buildings

UFC 4-020-01 DoD Security Engineering Facilities Planning Manual

UFC 4-020-03FA Security Engineering: Final Design

UFC 4-150-02 Dockside Utilities for Ship Service

UFC 4-150-06 Military Harbors and Coastal Facilities

 

UFC 4-152-01 Design: Piers and Wharves

UFC 4-179-01 Design: Navy Firefighting School Facilities

UFC 4-832-01N Design: Industrial and Oily Wastewater Control

UFC 4-911-01N O&M: Inactive Care and Closure of Shore Facilities

STANDARDS

MIL-STD-161 Identification Methods for Bulk Petroleum Products 

Systems Including Hydrocarbon Missile Fuels

MIL-STD-461 Requirements for the Control of Electromagnetic 

Interference Characteristics of Subsystems and 

Equipment

MIL-STD MS 24484 Adapter, Pressure Fuel Servicing, Nominal 2.5-inch 

Diameter

AIR FORCE 

AIR FORCE HANDBOOKS

AFH 32-1084 Facility Requirements
UFC 3-460-01

16 August 2010

A-5 

AIR FORCE INSTRUCTIONS (AFI)

AFI 32-1054 Corrosion Control

AIR FORCE MANUALS (AFM)

AFM 88-9 Electrical Design – Lightning and Static Electricity 

Protection

AFMAN 91-201 Explosives Safety Standards

OCCUPATIONAL SAFETY AND HEALTH

AFOSH 91-38 Hydrocarbon Fuels -- General

TECHNICAL MANUALS

 

AFTO 00-25-172 Ground Servicing of Aircraft and Static 

Grounding/Bonding 

AFTO 37-1-1 General Operation and Inspection of Installed Fuel 

Storage and Dispensing Systems

AFTO 42B1-1 Quality Control of Fuels and Lubricants

DEPARTMENT OF DEFENSE

DESC-X-P-2 DoD Fuel Filter Element Standardization Policy

NATO STANDARDS

 STANAG 3784 Technical Guidance For The Design And Construction 

Of Aviation And Ground Fuel Installations On NATO 

Airfields

 

U.S. ARMY CORPS OF ENGINEERS

Unless otherwise indicated, copies are available from the U.S. Army Corps of 

Engineers, Washington, D.C. 20314-1000. Many of the documents below are also 

available on the following website: the Whole Building Design Guide website provided 

by the National Institute of Building Sciences at http://www.wbdg.org/ccb. 

ENGINEER MANUAL

EM 1110-1-4006 Removal of Underground Storage Tanks
UFC 3-460-01

16 August 2010

A-6 

ENGINEER TECHNICAL LETTERS 

ETL 1110-3-466 Selection and Design of Oil/Water Separators at Army 

Facilities

ETL 1110-3-502 Telephone and Network Distribution System Design

 Implementation Guide

ETL 03-04 Alternative Fuels E85 and B20

REGULATION

AR 420-90 Fire and Emergency Services 

TECHNICAL MANUALS

TM 5-811-3 Electrical Design - Lightning and Static Electricity 

Protection

TM 5-811-9 Voice/Data Telephone Systems

NAVY DESIGN MANUALS, P-PUBLICATIONS, AND MAINTENANCE AND 

OPERATION MANUALS: 

Available from National Technical Information Service (NTIS), 5285 Port Royal Road, 

Springfield, VA 22161, Attention: Defense Publications. Many of the documents below 

are also available on the following website: the Whole Building Design Guide website 

provided by the National Institute of Building Sciences at http://www.wbdg.org/ccb. 

NAVAIR

NAVAIR 00-80R-14 NATOPS U.S. Navy Aircraft Fire Fighting and Rescue 

Manual 

NAVAIR 00-80T-109 Aircraft Refueling NATOPS Manual

NAVFAC

DEFINITIVE DRAWINGS

No. 1404000 Aircraft Direct Fueling System

Nos. 1403995 Non-Polluting Fuel Piers

 thru 1403999

No. 1404005 Truck Unloading System Design
UFC 3-460-01

16 August 2010

A-7 

INSTRUCTIONS

OPNAVINST 5090.1 Environmental Readiness Program Manual

OPNAVINST 5100.23 Navy Safety and Occupational Health (SOH) Manual

INTERIM TECHNICAL GUIDANCE

FY94-01 Cathodic Protection Systems

P-PUBLICATIONS

P-80/UFC 2-000-05N Facility Planning Criteria for Navy/Marine Corps 

Shore Installations

MAINTENANCE AND OPERATION MANUALS

MO-230 Petroleum Fuel Facilities

NAVSEA

NAVSEA S6340- Technical Manual for OTTO Fuel II 

AA-MMA-010 Safety, Storage, and Handling Instructions

GENERAL SERVICES ADMINISTRATION

COMMERCIAL ITEM DESCRIPTION

CID A-A-52557 Fuel Oil, Diesel; for Posts, Camps and Stations

CID A-A-59693 Diesel Fuel, Biodiesel Blend (B20)

CID A-A-59666 Cylinder, Compressed Gas

(Unless otherwise indicated, copies are available from: 

• GSA, 1800 F Street NW, Washington, D.C. 20405, Phone Number: (816) 823-

1219) (www.gsa.gov) 

• The Department of Defense Single Stock Point for Military Specifications, 

Standards and Related Publications at http://dodssp.daps.dla.mil/

OTHER GOVERNMENT DOCUMENTS AND PUBLICATIONS: 

CODE OF FEDERAL REGULATIONS (CFR)

29 CFR Part 1910 Occupational Safety and Health Standards
UFC 3-460-01

16 August 2010

A-8 

33 CFR Part 154 Facilities Transferring Oil or Hazardous Material in 

Bulk

40 CFR Part 60 Standards of Performance for New Stationary 

Sources

40 CFR Part 112 Oil Pollution Prevention

40 CFR Part 122 EPA Administered Permit Programs: The National 

Pollutant Discharge Elimination System (NPDES)

40 CFR Part 280 Technical Standards and Corrective Action 

Requirements for Owners and Operators of 

Underground Storage Tanks (UST)

40 CFR Part 281 Approval of State Underground Storage Tank 

Programs

49 CFR Part 195 Transportation of Hazardous Liquids by Pipeline

(Unless otherwise indicated, copies are available from the Superintendent of 

Documents, U.S. Government Printing Office (GPO), Washington, D.C. 20402.)

UNITED STATES CODE

42 USC 4321 National Environmental Policy Act (NEPA)
UFC 3-460-01

16 August 2010

A-9 

NON-GOVERNMENT PUBLICATIONS: 

AMERICAN CONFERENCE OF GOVERNMENTAL INDUSTRIAL HYGIENISTS 

(ACGIH)

-- Industrial Ventilation: A Manual of Recommended 

Practice for Design

(Unless otherwise indicated, copies are available from American Conference of 

Governmental Industrial Hygienists (ACGIH), 1330 Kemper Meadow Drive, Cincinnati, 

OH 45240. Phone Number: (513) 742-2020.) (www.acgih.org) 

AMERICAN CONCRETE INSTITUTE

ACI 350.4R-04 Design Considerations for Environmental Engineering 

Concrete Structures.

(Unless otherwise indicated, copies are available from American Concrete Institute, 

P.O. Box 9094, Farmington Hills, MI 48333-9094. Phone Number: (248) 848-3800.) 

(http://www.aci-int.org/general/home.asp) 

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)/AMERICAN SOCIETY OF 

MECHANICAL ENGINEERS (ASME)/INSTITUTE OF ELECTRICAL AND 

ELECTRONICS ENGINEERS (IEEE)

ASME BPVC Boiler and Pressure Vessel Code

ANSI/ASME B16.5 Pipe Flanges and Flanged Fittings

ANSI/ASME B16.47 Large Diameter Steel Flanges: NPS 26 through NPS

60 

ANSI/ASME B31.3 Process Piping

ANSI/ASME B31.4 Pipeline Transportation Systems for Liquid 

Hydrocarbons and other liquids

 

ANSI/IEEE 142 Recommended Practice for Grounding of Industrial 

and Commercial Power Systems

ANSI/IEEE 1100 Recommended Practice for Powering and Grounding 

Electronic Equipment

ANSI/IEEE C2 National Electrical Safety Code

 
UFC 3-460-01

16 August 2010

A-10

(Unless otherwise indicated, copies are available from the American National Standards 

Institute (ANSI), 25 West 3rd Street, New York, NY 10036, Phone Number: (202) 293-

8020 (www.ansi.org); American Society of Mechanical Engineers (ASME), 22 Law 

Drive, Fairfield, NJ 07007-2900, Phone Number: (973) 882-1170 (www.asme.org); and 

Electrical and Electronics Engineers (IEEE), Inc., IEEE Standards, 445 Hoes Street, 

Piscataway, NJ 08855-1331, Phone Number: (800) 701-4333 (www.ieee.org).) 

AMERICAN PETROLEUM INSTITUTE (API)

 

API 570 Piping Inspection Code: In-Service Inspection, 

Rating, Repair and Alteration of Piping Systems

Bulletin D16 Suggested Procedure for Development of Spill 

Prevention Control and Countermeasure Plans

MPMS 2 Tank Calibration

MPMS 3 Tank Gauging

MPMS 5 Metering

 

Publ 2202 Dismantling and Disposing of Steel from Tanks which 

have Contained Leaded Gasoline

RP 500 Recommended Practice for Classification of Locations 

for Electrical Installations at Petroleum Facilities – 

Classified as Class I, Division I and Division 2

RP 540 Electrical Installations in Petroleum Processing Plants

RP 651 Cathodic Protection of Aboveground Petroleum 

 Storage Tanks

 

RP 1004 Bottom Loading and Vapor Recovery for MC-306 

Tank Motor Vehicles

RP 1102 Steel Pipelines Crossing Railroads and Highways

RP 1110 Pressure Testing of Steel Pipelines for the 

Transportation of Gas, Petroleum Gas, Hazardous 

Liquids, Highly Volatile Liquids or Carbon-Dioxide

RP 1604 Closure of Underground Petroleum Storage Tanks

RP 1615 Installation of Underground Petroleum Storage 

Systems
UFC 3-460-01

16 August 2010

A-11

RP 1637 Using the API Color-Symbol System to Mark 

Equipment and Vehicles for Product Identification at

Gasoline Dispensing Facilities and Distribution 

Terminals

RP 2003 Protection Against Ignitions Arising Out of Static, 

Lightning, and Stray Currents

RP 2350 Overfill Protection for Storage Tanks in Petroleum 

Facilities

Spec 6D Specification for Pipeline 

Std 607 Testing of Valves – Fire Type-Testing Requirements

Std 608 Metal Ball Valves – Flanged, Threaded and ButtWelding Ends 

Std 610 Centrifugal Pumps for Petroleum, Petrochemical and 

Natural Gas Industries

Std 650 Welded Tanks for Oil Storage

Std 653 Tank Inspection, Repair, Alteration, and 

Reconstruction

Std 2000 Venting Atmospheric and Low-Pressure Storage 

Tanks

Std 2015 Requirements for Safe Entry and Cleaning of 

Petroleum Storage Tanks

Std 2510 Design and Construction of Liquefied Petroleum Gas 

(LPG) Installations

Std 2610 Design, Construction, Operation, Maintenance, and 

 Inspection of Terminal and Tank Facilities

(Unless otherwise indicated, copies are available from American Petroleum Institute 

(API), 1220 L Street NW, Washington, DC 20005-4070 (www.api.org).)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D910 Standard Specification for Aviation Gasoline (Avgas) 

ASTM D975 Standard Specification for Diesel Fuel Oils
UFC 3-460-01

16 August 2010

A-12

 

ASTM D1655 Standard Specification for Aviation Turbine Fuels 

(DoD Adopted)

ASTM D3699 Standard Specification for Kerosene

ASTM D4814 Standard Specification for Automotive Spark-Ignition 

Engine Fuel

ASTM D5798 Standard Specification for Fuel Ethanol (Ed75-Ed85) 

for Automotive Spark-Ignition Engines 

ASTM D6751 Standard Specification for Biodiesel Fuel Blend Stock 

(B100) for Middle Distillate Fuels

ASTM F758 Standard Specification for Smooth-Wall Poly (Vinyl 

Chloride) (PVC) Plastic Underdrain Systems for 

Highway, Airport, and Similar Drainage (DoD

Adopted)

(Unless otherwise indicated, copies are available from the American Society for Testing 

and Materials (ASTM), 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, 

Phone Number: (610) 832-9585 (www.astm.org).)

COMPRESSED GAS ASSOCIATION (CGA) 

Pamphlet G-7.1. Commodity Specification for Air

(Unless otherwise indicated, copies are available from the Compressed Gas 

Association, 4221 Walney Road, 5th Floor, Chantilly VA 20151-2923, Phone Number: 

(703) 788-2700 (www.cganet.com).)

COORDINATING RESEARCH COUNCIL, INC. (CRC)

Report No. 346 Electrostatic Discharges in Aircraft 

 Fuel Systems – Phase I

 

Report No. 355 Electrostatic Discharges in Aircraft 

 Fuel Systems – Phase II

Report No. 635 Handbook of Aviation Fuel Properties

 

(Unless otherwise indicated, copies are available from the Coordinating Research 

Council, Inc., 3650 Mansell Road, Suite 140, Alpharetta, GA 30022, Phone Number: 

(678) 795-0506 (www.crcao.com/.)

ENERGY INSTITUTE (EI) 
UFC 3-460-01

16 August 2010

A-13

EI Std 1529 Aviation Fueling Hose and Hose Assemblies (formerly 

API Std 1529)

EI Specification 1581 Specifications and Qualification Procedures for 

 Aviation Jet Fuel Filter/Separators (formerly API/IP 

Specification 1581)

(Unless otherwise indicated, copies are available from the Energy Institute (EI), 61 New 

Cavendish Street, London W1G 7AR, UK, Phone Number: +44 (0) 20-7467-7100 

(http://www.energyinst.org/).)

FACTORY MUTUAL ENGINEERING CORP. (FM)

Section 7-55 Loss Prevention Data, Liquid Petroleum Gas

(Unless otherwise indicated, copies are available from FM Global, 1301 Atwood 

Avenue, Johnston, RI 02919, Phone Number: (877)364-6726 

(www.fmglobaldatasheets.com).)

GAS PROCESSORS ASSOCIATION

Standard 2140 Liquefied Petroleum Gas Specifications and Test 

Methods

(Unless otherwise indicated, copies are available from Gas Processors Association, 

6526 East 60th Street, Tulsa, OK 74145 , Phone Number: (918)493-3872, 

(www.gpaglobal.org).)

GAS TECHNOLOGY INSTITUTE (GTI)

GTI-02/0136 CASCADE TM Gaseous Fueling System Sizing 

Software

(Unless otherwise indicated copies are available from the Gas Technology Institute, 

1700 South Mount Prospect Road, Des Plaines, IL 60018, Phone Number: (847) 768-

0500 (www.gastechnology.org).)

HYDRAULIC INSTITUTE

-- Individual Standards for Centrifugal, Vertical, Rotary, 

and Reciprocating Pumps, as well as General 

Guidelines for Pumps

(Unless otherwise indicated, copies are available from the Hydraulic Institute, 9 Sylvan 

Way, Parsippany, NJ 07054-3802, Phone Number: (973) 267-9700 (www.pumps.org).)
UFC 3-460-01

16 August 2010

A-14

INTERNATIONAL SAFETY EQUIPMENT ASSOCIATION (ISEA)

ISEA Z358.1 Emergency Eyewash and Shower Equipment 

(formerly ANSI Z358.1)

(Unless otherwise indicated, copies are available from the International Safety 

Equipment Association (ISEA), 1901 North Moore Street, Arlington, VA 22209-1762, 

Phone Number: (703) 525-1695 (www.safetyequipment.org).)

NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE) INTERNATIONAL

 SP0169 Control of External Corrosion on Underground or 

Submerged Metallic Piping Systems

(Unless otherwise indicated, copies are available from the National Association of 

Corrosion Engineers (NACE) International, 1440 South Creek Drive, Houston, TX 

77218-8340, Phone Number: (281) 228-6200 (www.nace.org/.)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 11 Standard for Low–, Medium–, and High – Expansion 

Foam

NFPA 20 Standard for the Installation of Stationary Pumps for 

Fire Protection

NFPA 30 Flammable and Combustible Liquids Code

NFPA 30A Code for Motor Fuel Dispensing Facilities and Repair 

Garages

NFPA 31 Standard for the Installation of Oil-Burning Equipment

NFPA 37 Standard for the Installation and Use of Stationary 

Combustion Engines and Gas Turbines

NFPA 45 Standard on Fire Protection for Laboratories Using 

Chemicals

NFPA 52 Vehicular Gaseous Fuel Systems Code

NFPA 54 National Fuel Gas Code

NFPA 55 Compressed Gases and Cryogenic Fluids Code

NFPA 58 Liquefied Petroleum Gas Code
UFC 3-460-01

16 August 2010

A-15

NFPA 59 Utility LP-Gas Plant Code

NFPA 70 National Electrical Code

NFPA 77 Recommended Practice on Static Electricity

NFPA 110 Standard for Emergency and Standby Power Systems

NFPA 307 Standard for the Construction and Fire Protection of 

Marine Terminals, Piers, and Wharves

NFPA 407 Standard for Aircraft Fuel Servicing

NFPA 415 Standard on Airport Terminal Buildings, Fueling Ramp 

Drainage, and Loading Walkways

NFPA 780 Standard for the Installation of Lightning Protection 

Systems

(Unless otherwise indicated, copies are available from the National Fire Protection 

Association (NFPA), 1 Batterymarch Park, Quincy, MA 02169-7471, (www.nfpa.org.)

UNDERWRITERS LABORATORIES, INC. (UL)

UL 58 Steel Underground Tanks for Flammable and 

Combustible Liquids

UL 142 Steel Aboveground Tanks for Flammable and 

Combustible Liquids

UL 1746 External Corrosion Protection Systems for Steel 

Underground StorageTanks

UL 2080 Fire Resistant Tanks for Flammable and Combustible 

Liquids

UL 2085 Protected Aboveground Tanks for Flammable and 

Combustible Liquids

(Unless otherwise indicated, copies are available from the Underwriters Laboratories, 

Inc. (UL), 333 Pfingsten Road, Northbrook, IL 60062-2096, Phone Number: (847) 272-

8800 (www.ul.com).)

SOCIETY OF AUTOMOTIVE ENGINEERS

AS5877 Detailed Specification for Aircraft Pressure Refueling 

Nozzle
UFC 3-460-01

16 August 2010

A-16

(Unless otherwise indicated, copies are available from SAE Customer Service, 400 

Commonwealth Drive, Warrendale, PA 15096-0001, Phone Number: (877) 606-7323 

(www.sae.org/). 

STEEL TANK INSTITUTE

STI P3 Specification and Manual for External Corrosion 

Protection of Underground Steel Storage Tanks

(Unless otherwise indicated, copies are available from the Steel Tank Institute, 944 

Donata Court, Lake Zurich, IL 60047, Phone Number: (847) 438-8265 

(www.steeltank.com/). 
UFC 3-460-01

16 August 2010

B-1 

APPENDIX B - MANUAL SURGE CALCULATIONS FOR SIMPLE PIPING SYSTEMS

(1) Determine the critical time of the system. This is defined as the time it takes for 

the first increment of the pressure wave to travel upstream, reflect, and return to 

the valve. Use the following equation:

EQUATION: Tc = 2L/a (1)

where:

Tc = critical closure time of system(s)

L = length of pipe (ft or m)

a = surge pressure wave velocity (fps or m/s)

Values for “a” for liquid petroleum in schedule 40 steel pipe are as follows. 

These values are based on hydrocarbons with a specific gravity of 0.8 at a 

temperature of 68 degrees F (20 degrees C):

Nominal Pipe Size

inches (mm)

Surge Pressure Wave 

Velocity, “a”

ft/s (m/s)

2 (50) 3,771 (1149.4)

3 (75) 3,763 (1147.0)

4 (100) 3,736 (1138.7)

6 (150) 3,692 (1125.3)

8 (200) 3,663 (1116.5)

10 (250) 3,639 (1109.2)

12 (300) 3,599 (1097.0)

(2) If valve closure time (T) is less than Tc, it is equivalent to instantaneous closure 

and will result in maximum surge pressure. The equation used to calculate surge

pressure rise for this situation is:

EQUATION: P1 - P = [(V1 - V0)(w)(a)] / [(C)(g)] (2)

where:

P1 = maximum pressure (psig or Pa) 

P = pump shutoff pressure (psig or Pa) (equal to system static pressure)

V1 = initial velocity (fps or m/s)

V0 = final velocity (fps or m/s)

w = specific weight of the fluid (lbm/ft3 or kg/m3) 

g = gravitational constant (32.2 ft/s2 or 9.81 m/s2

) 

C = unit constant (144 in2/ft2, 0.101 (kg/m2)/Pa

a = surge pressure wave velocity (fps or m/s)
UFC 3-460-01

16 August 2010

B-2 

(3) For example, a fuel storage facility has a truck loading rack located 2,000 feet 

(610 m) away. The load rack is fed by a 600 gpm (38 L/s) pump located at the 

storage facility. The load rack is equipped with a deadman apparatus which is 

tied to a hydraulically operated diaphragm control valve at the rack. The valve 

has a closure time of 1.0 seconds. The pipe is 6-inch (150 mm) diameter carbon 

steel, Schedule 40, with Class 150 flanges. The pump shutoff pressure is 60 

psig (410 kPa). Find the critical time of the system if the loading rack control 

valve closes.

Tc = 2L/a = 2×2,000/3,692 = 1.08 seconds

From the table of values for “a”, the surge pressure wave velocity (a) is 3,692 fps 

(1125.3 m/s). The maximum pressure in any pipeline occurs when the total

discharge is stopped in a period of time equal to or less than the critical time. 

Since the valve will theoretically close prior to this, Equation (2) should be used 

to determine the pressure rise. In this case, the final velocity (Vo) will be 

assumed to be zero because the critical time is greater than the valve closure 

time.

P1 – P = [(V1)(w)(a)] / [(144)(g)] 

= [(6.81×51.5×3,692)] / [(144×32.2)] = 279 psig (1925 kPa)

P1 = P+273 = 60+279 = 339 psi (2337 kPa)

Initial velocity (V1) was found by dividing the given flow rate of 600 gpm (38 L/s) 

by the cross sectional area of the 6-inch (150 mm) diameter, Schedule 40 pipe. 

Considerations will have to be made for this system to deal with the maximum 

predicted pressure.

(4) When the valve closure time is longer than the critical time, the surge will be less 

than predicted by Equation (2). The equation used to calculate surge pressure 

rise for this situation is:

EQUATION: P1 - P = [2(L)(w)(V1 - Vc)] / [1.3 (C)(g)(T)] (3)

where:

P1 = maximum pressure (psig or Pa)

P = pump shutoff pressure (psig or Pa) (equal to system static pressure)

L = length of pipe (ft or m)

V1 = initial velocity (fps or m/s)

Vc = velocity at Tc (fps or m/s)

w = specific weight of the fluid (lbm/ft3 or kg/m3) 

g = gravitational constant (32.2 ft/s2 or 9.81 m/s2) 

C = unit constant (144 in2/ft2, 0.101 (kg/m2)/Pa

a = surge pressure wave velocity (fps or m/s)

T = valve closure time (sec)

Determination of Vc is too complex for simple calculation. Therefore, for the 

conditions where T > Tc, use a computer modeling program.
UFC 3-460-01

16 August 2010

C-1 

APPENDIX C - CHARTER OF DoD FUELS FACILITY ENGINEERING PANEL

A. INTRODUCTION

1. To benefit from Department of Defense (DoD) wide petroleum, oils, and lubricants 

(POL) expertise and apply it to fuel handling issues facing the DoD, an ad hoc group 

known as the Fuels Facility Engineering Panel (FFEP) is hereby established. The 

DoD FFEP (Panel) is an association of recognized POL experts, primarily from the 

engineering community, and is established to advise the DoD community on ways to 

provide safe, operationally effective, and economic DoD fuel handling systems. The 

Panel will examine, develop, and recommend design features for the standardization 

of facilities and equipment, and procedures used in fuel handling systems for 

storage, distribution, maintenance and dispensing of aircraft, marine, and ground 

fuel. The Panel will evaluate facility component parts on DoD installations and will 

serve as a pool of expertise to assist in resolving systemic fuel handling facility 

problems. Panel meetings will also serve as a forum to update members on new 

equipment, DoD or service-specific programs, and changes affecting the fuels 

maintenance/repair community.

B. COMPOSITION

1. Voting members:

a) Air Force Fuels Engineer (HQ AFCESA/CEOA) 

b) NAVFAC POL Facility Subject Matter Expert (NFESC)

c) HQ Army Corps of Engineers Technical POC, POL Facility Criteria (CECW-CE)

d) The Defense Energy Support Center – Facilities Engineer (DESC-WI)

2. Coordinating members:

a) Defense Logistics Agency 

b) Defense Fuel Region Facility Managers 

c) AF MAJCOM Fuels Engineers

d) AF Petroleum Office Fuels Technical Assistance Team Members 

e) NOLSC Fuels Facility Engineers

f) NAVAIR Fuels Engineers

g) NAVFACENGCOM, Fuels Facility Engineers 

h) Army APC Fuel Facility Team Members

i) Army Corps of Engineers, Huntsville Division, Technical POC, POL Facility 

Criteria

j) Army Corps of Engineers, Omaha District, POL Facility Design Center of 

Expertise

3. The Chairperson will be rotated biennially among the voting members.

C. TASKS

1. Tasks of the FFEP include but are not limited to:

a) Develop standardized designs for receipt, storage, and dispensing of fuels.

b) Periodically review and update UFC 3-460-01, including referenced DoD fuel 

handling facility criteria, and fuel system maintenance and repair criteria.
UFC 3-460-01

16 August 2010

C-2 

 c) Perform technical review of new or proposed design standards or concepts.

d) Review system operational problems, including components and materials, and 

recommend corrections.

e) Cross-feed information such as problems and solutions, new missions and 

equipment, needed modifications to equipment, and new DoD or Service-wide 

programs and periodically communicate this information in a newsletter.

f) Provide a means of communication among the Air Force, Army, Navy, and 

Defense Energy Support Center to reduce duplication and effect DoD-wide 

Standardization.

g) Review training and utilization of fuel handling system maintenance personnel 

and recommend improvements.

h) Provide information to fueling operations personnel to assure proper operation 

of equipment.

i) Assess the impact of environmental regulations on POL design, and develop 

designs that will address these impacts.

2. Substantive Deviations, or departures from design standards in UFC 3-460-01, must 

be approved by the FFEP.

D. MEETINGS

1. The Panel will meet at the call of the Chairperson but not less than once per year. 

Voting members may request a meeting at any time.

2. Decisions of the FFEP will be made by achieving consensus among the voting 

members of the FFEP.

E. CHARTER REVIEW

1. The Panel will review the Charter at least once per year, and update as required.