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CHAPTER 10

PETROLEUM INSTALLATION MAINTENANCE

Section I. Tank Farms and Pipeline Surroundings

MAINTENANCE OF SURROUNDINGS

The primary purpose of good maintenance practices at petroleum installations is to enhancesafety and security and to maximize service life. These practices also enhance work forceperformance and public relations. Working personnel, military or civilian, perform better whenhigh standards of safety, cleanliness, orderliness, and appearance are maintained. This appliesto all facilities, whether permanent, semipermanent, or temporary. Under any conditions, fireprevention, integrity of firewalls, safety, security, and environmental protection stewardshipmust be considered in all petroleum installation maintenance procedures and policies.

GROUNDS

Constant attention should be paid to the installation grounds and the property aroundpipelines. All areas should be attractive and free of fire hazards. To maintain the grounds,follow these steps.

Mow grassy areas regularly.Use approved environmentally safe procedures for removal of unwanted plants fromgrowing inside of firewalls, near fire hydrants, around tank openings, and in fuel handlingareas of operation.Collect litter, trash, fallen leaves, and other combustible materials.Cut overgrown bushes and foliage around pipelines to permit patrolling and easy accessto control valves."No Smoking" and "Confined Space Entry Requirements" signs posted are in good conditionand legible at a distance.

BUILDINGS AND SHELTERS

Buildings, pump station shelters, toolsheds, and all other similar structures should be kept ingood condition To maintain them, follow these rules.

Inspect all painted areas for flaking or blistered paint. Report areas that needrepainting.

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Check the condition of roof gutters and downspouts. Report any needed repairs.Remove any items that could become fire or safety hazards. Follow general housekeepingprocedures.Keep pump stations dry, clean, and well ventilated with approved adequate lightingdevices.

FIREWALLS AND TANK MOUNDS

The firewalls which are built around aboveground tanks at permanent installations are usuallymade of concrete or some impervious material. These firewalls are subject to damage. Themounds of earth that cover underground tanks and the earthen firewalls (Figure 10-1) whichare built around aboveground tanks in tactical areas are subject to erosion. If left unchecked,erosion weakens firewalls so that they are not able to act as a secondary containment for aspill or prevention of a fire from spreading to another source. Also, the eroded soil collects atthe base of the firewalls. This destroys the grade inside the firewalls so that runoff waterflows to the tank instead of from it. The water corrodes the tank bottom. It also washesaway soil under the tank, causing the tank to settle. This settling puts stress on the tankstructure and pipes. To maintain firewalls and tank mounds, follow these rules.

Check concrete firewalls regularly for cracks and other signs of damage. Report anydeterioration.Fill in eroded areas in earthen mounds and firewalls as soon as possible.Regrade earthen firewalls so that water flows away from the tank.Seed the filled in areas of tank mounds and the outside slopes of firewalls with grass orvines, or with gravel or an asphalt like substance to hold soil in place.Dress the inside slopes frequently to replace eroded soil; cover the inside slopes withgravel or perma prime. Another possibility is to arrange for the inside slopes to be withconcrete. Another way to protect the ground is to cover the surface with rubberized orpetroleum impervious sheets within the earthen berms.

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Figure 10-1. Earthen firewall

PIPELINE SUPPORTS

Hangers and tiedowns as shown in Figure 10-2 are used to attach pipelines to bridges andtrestles. Concrete embedded pipe anchors as shown in Figure 10-3, page 10-3, are used alongpipelines to control movement and reduce vibrations. Other devices, such as wire ropes, cables,tower timbers, cross braces, and deadman anchors, are used to suspend pipelines acrossstreams and ravines. To maintain pipeline supports, follow these steps:

Inspect all devices monthly for warped and loose hardware, breaks, and corrosion. Repair,tighten, or replace the hardware as needed.Allow enough space for the pipeline to expand in hot weather areas or to contract incold weather areas when tightening fixtures.Inspect concrete foundations and the steel rods of pipe anchors for signs of damage orcorrosion every 3 months during the first year after construction and then every 6months thereafter.

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Figure 10-2. Pipeline hangers and tie downs

Figure 10-3. Pipeline anchors

WALKWAYS, RAILROAD TRACKS, AND CULVERTS

The roads, walkways, railroad tracks, and culverts required to operate a petroleum installation

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should be safe. To maintain them, follow these steps.

Patch or repair potholes and cracks as soon as possible.Fill in washed-out areas beneath roads and walkways before more damage results.Ensure the railroad tracks in loading/unloading areas for tank cars are well maintained.Check the alignment and condition of rails and ties. Look for loose spikes, worn or looseswitches, or unserviceable grounding systems.Keep pipeline culverts under roads, railroad tracks, and water crossings clean. Inspectculverts after every heavy storm. Check them frequently during rainy weather and inthe spring after the snow melts and the ground thaws. Remove any debris and sedimentthat may have collected.

SECURITY FENCES

Fences are necessary around petroleum installations to prevent trespassing, theft andsabotage. To maintain the security fences, follow these steps.

Inspect the fencing, entrance gates, and fence posts regularly. Repair defective areasimmediately.Promptly fill in gaps created by erosion or animals burrowing under the fences.

Section II. Waterfront Facilities

MAINTENANCE OF WATERFRONT FACILITIES

Waterfront facilities and tactical marine terminals are used to transfer fuel to and fromtankers. Maintenance on the waterfront is a constant effort to stop the potential threat tothe environment caused by the sea, ships, and weather conditions A regular program ofinspections and maintenance is necessary to prevent as much damage as possible from theseawater, salt, air, marine organisms, sunlight, and dry rot. Furthermore, there are strictenvironmental regulations, permits and SPCC Plans which require that certain maintenance bedone on a strict time schedule. Every effort must be made to ensure these rules and timeschedules are followed, both to the letter, and the spirit of their intent. Emergency repairsare also necessary to mend the structural damage caused by moving vessels, ice, petroleumspills, and high waves. Ongoing maintenance is essential to keep waterfront facilities andmarine terminals operational.

RESPONSIBILITY FOR WATERFRONT MAINTENANCE

Repairs to structures such as piers and pilings cannot be done by organizational maintenancepersonnel. However, they are responsible for maintaining the pipelines, hoses, hose-handlingequipment, grounding systems, and mooring devices at waterfront operations.

FUEL PIER AND JETTY PIPELINES

Pipelines on fuel piers and jetties as shown in Figure 10-4, are used in protected harbors totransfer fuel. The piers and jetties are usually equipped with several pipelines to carry

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different fuels. The pipelines may be supported on top of a pier or jetty, or they may besuspended below a pier with hangers (Figure 10-5). Pipelines under piers are especially subjectto damage because they are alternately submerged and exposed by tides. To maintain thepipeline system--

Inspect the pipelines, supports, and hangers frequently. Look for corrosion, chipped paint,and any signs that the protective coatings have failed.Sand the damaged areas to bare metal if necessary. Apply an protective coatingmaterial such as zinc chromate, and then spot paint the pipeline, metal supports, andhangers.

Figure 10-4. Multileg mooring facility

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Figure 10-5. Pipelines under a fuel pier

SUBMARINE PIPELINES

Submarine pipelines are welded pipe sections connected to storage tanks on shore and laidunder water to ship moorings. These pipelines are located at tactical marine terminals. Theyare also located in areas that are not navigable by ships and in areas where there are nopiers. Like the pipelines suspended under piers, submarine pipelines are especially prone tocorrosion and damage from the ocean. The onshore sections should be inspected frequently andrepaired as required. The underwater sections should be reported to support units. Themarker buoys for submarine pipelines and the chains used to lift the lines off the ocean floorshould be serviced the same as for the markers and chains of the mooring facilities.

HOSELINES

Wire-reinforced neoprene rubber hoses are flanged to the ends of submarine and pierpipelines. They provide flexible connections to tankers. Maintenance procedures of thehoselines include the following.

Inspect the hoses for damage such as kinks, bulges, worn soft spots, and cuts thatpenetrate the wire reinforcement. Look inside the open ends for internal damage.Repair or replace hose sections, couplings, and gaskets as needed.Keep the hoses tightly capped when not in use.Test each hose to 1 1/2 times its normal working pressure every 3 months. See Table 10-1.

WARNING

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Do not go over 125 PSI unless it can be determined that the hoses were designed bythe manufacturer to take more. During testing, look for leaks, bulges, and distortions inthe hose. Stencil the date of the test on the hose in a subdued color (black or gray)and keep a written record of the tests.

Table 10-1. Hose test pressures.

TYPE SIZE(in)

TESTPRESSURE

(PSI)

Hose assemblies, rubber, oil andgasoline discharge, smooth-bore,lightweight buoyant type (MIL-H-19001 (ships)) (latest revision)

Hose and hose assemblies, syntheticrubber, reinforced, water- and oilresistant, nonmagnetic and regularservice, high-pressure type (type C)(MIL-H-19606 (ships)) (latestrevision)

Hose and hose assemblies, rubber,oil- and gasoline discharge, smooth-bore, lightweight, buoyant type;reattachable couplings and adapters(MIL-H-22240 (ships)) (latestrevision)

Hose, rubber, gasoline, with reusablecouplings, low temperature (MIL-H-6615, latest revision)

6

4

4

5

6

6

7

4

200

1,200

800*

1,000

700

300

250

160

* TYPE D.

HOSE-HANDLING EQUIPMENT

Hose-handling equipment consists of devices such as cranes, slings, hoists, winches, A-frames,and gin poles. This equipment is usually located at the end of piers. It is used to lift andsuspend cargo hoses for fuel transfer. It is rigged to allow movement of the ship duringtransfer operations. Maintenance requirements of hose-handling equipment include thefollowing.

Lubricate all moving parts that are visible.Check for structural damage such as dents, buckling, cracks, and rust.Tighten all loose nuts on bolts and any other loose fixtures.Oil wire cables to keep them rust free.Test wire cables at least every 6 months.

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MARINE LOADING ARMS

Marine loading arms (Chapter 4) are being used instead of hoses and hose-handling equipmentat many waterfront facilities. Marine loading arms have a hydraulics system or a set of cableswhich moves the piping into position. Swivel joints provide a flexible connection between thepiping and a tanker. Maintenance requirements of marine loading arms include the following.

Lubricate the ball bearings in the swivel joints.Replace the packing, seals, and O-rings if a leak develops in the swivel joints. Follow theinstructions in the manufacturer’s manual.Inspect the outside surface for rust. If necessary, scrape to bare metal and then spotpaint with primer and rust-inhibiting semigloss enamel.Check the hydraulic fluid in the hydraulic arm. See the manufacturer’s manual for moreinformation.

WARNING

Do Not adjust the cables in a cable-operated arm. This is not organizational levelmaintenance.

LINE-HANDLING EQUIPMENT

Bollards, bits, and capstans are hardware devices used to moor a ship to a pier or jetty. Thesedevices are made of cast iron or steel. They are fastened to the pier with anchor bolts. Linehandling devices are subject to corrosion. The anchor bolts are especially subject to corrosionwhere they come in contact with the castings. Maintenance requirements of line handlingequipment include the following.

Grout under the castings and coat the anchor bolts, nuts, and washers with asphaltenamel.Inspect` the grouting and coatings often and repair them as needed.

MOORING FACILITIES

A multileg mooring facility (Figure 10-4) is used to anchor a tanker in position offshore duringa fuel transfer. A mooring facility is located at the ocean end of submarine pipelines.Depending on the size of the tankers to be moored, the mooring facility can have three, five,or seven legs as shown in Figure 10-6. Each leg of a multileg mooring facility is made up of amarker buoy, sinker, anchor, and chain. The chains and buoys are subject to much wear andtear from the ocean and moving vessels. Maintenance requirements of the mooring facilitiesinclude the following.

Lift the chains and inspect them for corrosion and uneven wear at least once a year.Clean and recoat the chains if necessary. Replace worn chains.Make sure cotter keys and forelock pins are securely in place in mooring chains.Inspect buoys frequently.

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Lift, sandblast, and recoat buoys with anticorrosive primer and antifouling paint at leastonce a year to keep them watertight and to prevent corrosion.

Figure 10-6. Typical mooring

PIER GROUNDING SYSTEMS

All the metal structures and pipelines on piers should be grounded. Also, ships and tankersshould be grounded and bonded with a flexible copper cable during fuel transfers. Maintenancerequirements for the pier grounding systems include the following.

Check all cables for positive connection before each transfer operation of fuels.Ensure all cables have a C-clamp or a device with sharp teeth or prongs to makecontact with the metal under the painted surface of the shipTest the system frequently. Replace broken wires and tighten loose connections asneeded.