USACE / NAVFAC / AFCESA / NASA UFGS-33 59 00 (April 2007)
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Preparing Activity: USACE Superseding
UFGS-33 56 17 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 33 59 00
TIGHTNESS TESTING OF EXISTING UNDERGROUND FUEL SYSTEMS
04/07
NOTE: This guide specification covers the requirements for tightness testing
procedures of existing underground fuel storage tanks and related piping systems
that are required to comply with 40 CFR 280.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
PART 1 GENERAL
NOTE: This specification is written such that a system's operating fuel is
to be used as the test medium for the tests defined herein. If water is required
as the test medium, the designer will be responsible for modifying the specification
accordingly. The main problems associated with using water as the test medium
are high disposal costs and fuel contamination.
The following is a list of suggested conditions that should be met when using
fuel as a test medium:
1. Tested systems are not offshore related.
2. Tested systems are not in close proximity to environmentally sensitive areas.
3. Tested systems are not in close proximity to highly populated areas.
4. Facilities within 300 feet of the tested systems are unoccupied at the
time of the tests.
5. Tested systems are kept under constant surveillance during the test.
6. Suitable contingency response equipment and personnel for spill cleanup
are on-call during testing.
If a leak is confirmed by the tests defined herein, a separate contract should
be developed to correct the problems. A separate contract is recommended because
work involving the location and repair of leaks, the excavation of soil, repeat
testing of the tank and piping, isolation of the piping and tank, the transfer
of fuel, and the restoration of surfaces would be very difficult if not impossible
for a Contractor to bid prior to performing any testing.
If, however, a decision is made to incorporate the work mentioned above into
this specification, the contract will have to be designed to allow a Contractor
to bid on the work mentioned above on a cost per occurrence or a cost per quantity
basis (i.e. cost per cubic meter (yard) for excavation).
Following any repairs, require tightness testing procedures be performed again
on the repaired area.
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[AMERICAN PETROLEUM INSTITUTE (API)API 570(1998; Addendum 1 2000, Addendum 2 2001, Addendum 3 2003, Addendum 4 2006) Piping Inspection CodeAPI RP 1110(2007) Pressure Testing of Liquid Petroleum Pipelines][ASME INTERNATIONAL (ASME)ASME B31.3(2008) Process Piping][ASTM INTERNATIONAL (ASTM)ASTM D 396(2008b) Standard Specification for Fuel OilsASTM D 975(2008ae1) Standard Specification for Diesel Fuel Oils]1.2 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] Submit the following in
accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Test Plan[; G][; G, [_____]]
SD-03 Product Data
Tightness Tests
SD-04 Samples
Fuel Supply
SD-06 Test Reports
Tightness Tests[; G][; G, [_____]]
SD-07 Certificates
Qualifications
API Inspection
Fuel Supply[; G][; G, [_____]]
Fuel Spills
Confirmed Leakage
1.3 QUALITY ASSURANCE
1.3.1 Qualifications
NOTE: Include any state and local regulatory requirements or certifications
that must be met by testing personnel.
Personnel responsible for performing the tightness testing shall be trained and certified by the equipment vendors
to use the test equipment needed to perform the tightness test. Each certified individual shall have a current
certification number from the test equipment vendor. Submit evidence of the testing personnel's experience,
training, and certification to use the test equipment.
1.3.2 Regulatory Requirements
NOTE: Some states and local governments have additional evaluation methods
and standards to be met (i.e. third party testing, the limit of the release
detection method to certain size (capacity) tanks, etc.). Include these methods
or standards if applicable.
The type of tightness test to be performed shall meet applicable federal, state, and local requirements as well
as the requirements within this section.
1.3.3 API Inspection
NOTE: Only include this paragraph if the utmost in accuracy and assurance is
required in a particular project. Note that an API 570 inspector can add a
significant cost to a project; however in turn the inspector can assure the
Government that the test results are accurate and that the testing truly conforms
to the required testing standards (e.g., API RP 1110).
Tightness testing policies, procedures, and results shall be inspected and approved by an authorized piping inspector
that is certified in accordance with API 570. Submit evidence of the inspector's experience and certification.
Following testing, submit evidence of the inspector's approval of the test results.
1.4 PROJECT/SITE CONDITIONS
NOTE: For tightness testing projects, develop design drawings that show the
approximate location and layout of each storage tank and piping system to be tested.
For each storage tank, include on the drawings the nominal tank volume (liters
(gallons)), the tank contents, the type of tank (FRP or steel), the date of
installation, and the date the last tightness test was performed if applicable.
Also indicate on the drawings the groundwater level at each site. If the groundwater
level is continually above the bottom of a tank, then require on the drawings
the installation of a 50 mm (2 inch) PVC pipe that would extend 610 mm (2 feet)
below the tank bottom. Require the pipe to be used for monitoring groundwater
levels during the tightness tests. Following the tightness tests, require the
Contractor to remove the pipe and fill the hole.
1.4.1 Property Damage
The Contractor is responsible for assuring that contamination and damage to tank products, the tank, and the
piping does not occur from the testing procedures. If at any time any Government or private property is damaged
or destroyed by any of the testing procedures or personnel, immediate notification shall be given to the Contracting
Officer.
1.4.2 Fuel Supply
NOTE: For volumetric testing, determine if the agency that is responsible for
fuel delivery will be willing to supply the fuel products necessary for topping
off a tank (above the 95 percent liquid level) since this would be the most
desired alternative. If the fueling agency will not supply the additional fuel
required, then this paragraph will need to be modified to require the Contractor
to provide the additional fuel. Note, however, that a Contractor will not be
able to supply aviation type fuels (JP-4, JP-5, JP-8, etc.) since these fuels
are not commercially available. A Contractor can only be required to supply
non-aviation type fuels (i.e., gasoline, diesel, fuel oils, etc.). Fuel to
be supplied by the Contractor must be specified in Part 2 of this section.
If fuel is to be supplied by the Contractor, then the submittal "Fuel Supply"
will remain in the specification. If fuel is only to be supplied by the Government,
then the submittal "Fuel Supply" will be deleted from the specification.
Fuel required for the testing of storage tanks and related piping systems as specified in this section [will
be provided by the Government] [shall be provided by the Contractor]. The [Government will] [Contractor shall]
furnish the tank trucks, operators, equipment, and services required for the fueling operations, except as modified
herein. [Fuel to be supplied shall meet the quality requirements as specified in paragraph "Fuels".] Provide
the labor, equipment, appliances, and materials required for the testing procedures. Do not test systems with
any fuel or liquid not intended for final system operation. Fuel used in the system shall remain the property
of the Government. Fuel shortages not attributable to normal handling losses shall be reimbursed to the Government.
Record material transfers and reconcile inventory records. [Submit a letter, at least [30] [_____] days prior
to fuel delivery, stating the amount of fuel required for testing the system. In the submittal, define the required
dates of each fuel delivery.] [Submit one fuel sample of each individual fuel type, prior to any tank filling
process, taken from the fuel supply to be provided. The Contracting Officer may reserve the right to have the
submitted samples tested by a chemical laboratory in order to verify each sample's quality. The Government will
be responsible for the expense of any tests performed upon the fuel samples.]
1.4.3 Fuel Spills
In the event any fuel product spill results during the testing procedures specified herein, give immediate verbal
notification to the Contracting Officer. Following verbal notification, submit within [2] [_____] days a written
statement that indicates the type of substance spilled, quantity, the location of the accident, the reason for
spillage, a list of any cleanup procedures taken, and a list of any personnel injuries. Stop testing procedures
immediately until notification is given by the Contracting Officer to begin testing again.
PART 2 PRODUCTS
2.1 FUELS
NOTE: If fuel is to be provided by the Government, delete this paragraph.
2.1.1 Diesel
Provide diesel that conforms to ASTM D 975.
2.1.2 No. 2, 4, 5, and 6 Fuel Oils
Provide fuel oil(s) that conforms to ASTM D 396.
PART 3 EXECUTION
3.1 PREPARATION
3.1.1 Test Plan
Prior to performing any site preparation work, prepare a test plan that addresses the following items for each
of the storage tanks and piping systems to be tested.
3.1.1.1 Test Method
Include a complete description of the proposed tightness test method to be performed. Include equipment and
step-by-step procedures required in the tightness test. Explain the accuracy involved with identifying the approximate
location of a leak.
3.1.1.2 Detail Drawings/Schematics
Include [detail drawings] [schematics] that indicate the location of the test points for each system and the
points where existing piping is to be isolated. Indicate specifically how existing product pipes are to be isolated
and tested. Define any demolition or alteration (permanent or temporary) to existing tanks and piping that may
be required in order to perform the tightness tests.
3.1.1.3 Downtime
Indicate the maximum amount of downtime that will be required for each system to be tested. If the testing procedures
can be performed while a fueling system is under operation, then the test plan shall indicate any required coordination
between the testing personnel and the fueling system operators.
3.1.1.4 Site Preparation Procedures
Include a list of site preparation procedures, if applicable, to be performed by the Contractor in preparing
each storage tank and piping system for testing.
3.1.2 Site Preparation
Prior to performing the tightness tests, perform the site preparation procedures as defined and approved in the
test plan. Secure each testing site with blockades and safety barriers to prevent unwanted entry. Inspect and
tighten accessible fittings and equipment connections if applicable.
3.2 FIELD QUALITY CONTROL
3.2.1 Tightness Tests
Note: The 0.1 gallon per hour leak rate is specified in 40 CFR 280 for tank
tightness testing and for line tightness testing. If state or local requirements
specify a more stringent leak rate detection, then insert that value.
Nonvolumetric tightness testing may not provide an exact leak rate, however
the method should provide an analysis of the system in relation to the specified
leak rate at a minimum probability of detection of 0.95 and a minimum probability
of false alarm of 0.05.
Tests used on both a storage tank and piping system shall be capable of detecting a [0.38 liter (1 gallon) 0.1
gallon] [_____] per hour leak rate with a minimum probability of detection of 0.95 and a minimum probability
of false alarm of 0.05. Isolate and test each storage tank and piping system separately. Do not install permanent
monitoring wells for monitoring groundwater levels. Isolate equipment such as pumps, filters, and meters from
the piping system during the testing. Do not exceed the pressure rating of any component in the piping system
during the testing. Submit shop drawings that show the manufacturer's brand names and catalog numbers of the
testing equipment and accessories required in performing the tightness tests. The catalog data shall be in sufficient
detail to demonstrate that the release detection equipment meets the specified requirements of this section.
3.2.1.1 Tank Tests
NOTE: Delete the bracketed sentence if waste oil tanks are not to be tested.
If volumetric testing is allowed, coordinate the fuel requirements with the
previous paragraph Fuel Supply.
Tests shall be capable of detecting a leak from any portion of the tank that routinely contains product while
accounting for the effects of thermal expansion or contraction of the product, vapor pockets, tank end deflections,
evaporation or condensation, temperature change, wind, vibration, noise, and the location of the water table.
Acceptable tank tightness testing methods shall be either volumetric or nonvolumetric as described in this section.
[Waste oil tanks shall only be tested using nonvolumetric testing.]
a. Volumetric Testing. Tests shall be the constant-level type. Temperature sensors shall
have a precision of 0.001 degrees F 0.002 degrees C or less. Test methods requiring only a
partially filled tank shall record data at intervals of 1 second or less. Test methods requiring
a tank to be filled above the 95 percent capacity level shall record data at intervals of 5
minutes of less. Tests shall not be conducted through any type of drop tube internal to a storage
tank. Tanks filled above the 95 percent level shall initially be filled to the 95 percent liquid
level and allowed 24 hours to stabilize. Following the 24 hour period and if applicable, top
off the tank as required and allow 3 hours to stabilize prior to testing.
b. Nonvolumetric Testing. Nonvolumetric test methods shall be capable of testing the entire
volume of a tank and not just the volume containing liquid on the day of the test. Vacuum tests
shall not damage the integrity of a storage tank.
3.2.1.2 Product Piping Tests
NOTE: Indicate on the drawings the normal working pressure of each pressure
piping system to be tested.
Tests shall account for temperature gains and/or losses experienced during the test period. Acceptable tightness
testing methods shall be either volumetric, nonvolumetric, or hydrostatic as described in this section.
a. Volumetric Testing. Temperature sensors shall have a precision of 0.001 degrees F 0.002
degrees C or less.
b. Nonvolumetric Testing. Nonvolumetric test methods shall be capable of testing the entire
volume of the piping. Vacuum tests shall not damage the integrity of the piping.
c. Hydrostatic Testing. Hydrostatically test product piping with the system's operating fuel
in accordance with ASME B31.3 and API RP 1110, except as modified herein, for a minimum 8 hour
period. Hydrostatically test pressurized piping systems at not less than 1-1/2 times the normal
working pressure but not less than [690 kPa 100 psi] [_____]. Use gauges for measuring the
leak rate that have increments small enough to detect a leak of [0.38 liter (0.1 gallon) 0.1
gallon] [_____] per hour or less. Taps for gauges or pressurizing pumps shall be on either
flanged connections or on temporary piping. Do not install taps on any permanent piping. Tests
shall validate that no leakage or reduction in gauge pressure occurred during the test period.
3.2.1.3 Confirmed Leakage
If a storage tank or pipe line is determined to be leaking based on the tightness tests performed, then testing
shall be stopped, hydrostatic or vacuum pressures shall be relieved, the entire system shall be visually inspected,
and immediate verbal notification shall be provided to the Contracting Officer. Following verbal notification,
submit within [2] [_____] days a written statement that lists the possible areas where the leakage is occurring,
the type of leakage (i.e. fuel or ground water), the approximate leak rate, etc. Piping systems determined to
be leaking shall remain in the isolated condition unless notified otherwise by the Contracting Officer.
3.2.1.4 Testing Acceptance
A storage tank and related product lines that withstand the tightness tests performed herein shall meet the testing
acceptance of this section. Do not reinstall until the entire system has passed each specified tightness test.
3.2.1.5 System Reinstallation
Following the testing acceptance of a system, thoroughly clean disconnected piping to prevent any dirt or contaminant
from entering into the tank system. Reassemble the entire system to match initial conditions and to be capable
of complete operation. Coordinate adjustments required to make a system operational with the Contracting Officer.
Coordinate final operational testing of a system with the Contracting Officer.
3.2.2 Inspections
NOTE: Delete any of the inspection items that are inapplicable. Add to the
inspection list any items that are more site specific.
Prior to any final operational testing, visually inspect each tank system to assure that the system is correctly
reassembled to match initial conditions. Report any component of the tank system damaged during the tightness
tests immediately to the Contracting Officer. During the inspection, verify the following as a minimum:
1. The piping system is correctly connected to each storage tank.
2. The piping's protective coating was not damaged during the testing.
3. The storage tanks were not damaged during the testing.
4. Buried utility warning tape uncovered or damaged during the testing was replaced.
5. The piping's secondary containment system was not damaged during testing.
6. Each tank and pipe line cathodic protection system is connected and performing properly.