You are on page 1of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical

Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

1.5

PETROLEUM INSTALLATION (GENERAL)


With OA, check valve pits, ducts, chambers, pump houses, dispensing/offloading points and access ways. Ensure the areas are clear from combustible materials, explosive hazards, loose equipment and materials. Monitor and report corrosion and damage. Report leaks or weeps of pipework and equipment promptly. Ensure access ways such as paths, stairs and walkways and safety rails are free from obstructions, hazards and damage AS 2885.3 (applicable to both high and low pressure pipelines for the purpose of this document). AS 2865.

1.51

MA

1.52

Inspect tunnels, shafts, valve pits and other structures including stairs, rails and catwalks for structural integrity, corrosion, protective coating integrity, being mindful of the requirements of confined space entry.

MA

1.53

Housekeeping - by inspection and cleaning as necessary ensure the facility and all its equipments, particularly guarding, safety and emergency equipment and systems is in a clean and sound state and access ways are clear and well marked. The MA will ensure that at the completion of all maintenance work, the work area and the specific equipment is left in a clean and tidy state and all waste materials and any hydrocarbons have been removed and correctly disposed of.

MA

Good housekeeping is one indicator of a well managed facility and reflects maintainer pride of ownership in a facility. Good housekeeping also contributes to plant safety and assists in identifying potential hazards and equipment items requiring maintenance or operational attention.

1.54

Inspect safety signs, labels, notices and posters IAW Commonwealth/State/Territory Legislation and Regulations, related Australian Standards and Defence Instructions to ensure that they are: a) appropriate in warnings; b) adequate in emergency procedure advice; c) securely fixed; d) clearly readable at normal operating or maintenance positions and correctly identify the equipment or appliance and/or its purpose; e) located and displayed prominently. Repair as required.

A schedule/drawing detailing type and location of all safety and operational signage is to be maintained by the MA addressing: Commonwealth/State/Territory Legislation and Regulations, Defence Instructions. AS 1940 AS 1319 a) b) c) d) e) f) g) h) electrical, personal safety, access, hazard identification, personal protection, instructional, security, and advisory

MA

1.55

With OA, check grass, lawns and general surrounds. Check that all fences, buildings and stands have grass cleared within 150mm of their perimeters; and lawns are neat and tidy. Cut back and remove excessive growth in vegetation. Ensure general surrounds are left neat and tidy after work completion inspection with OA.

AS1940

MA

As per service frequency or as required / on condition. MA to ensure correct Work Permits and Hot Work clearances are issued and understood where activity is in a designated Hazardous Area

1.56

Clean out all internal sections of bund and drain valve areas as required.

MA

As per service frequency or as required / on condition. Carry out in accordance with Base housekeeping requirements.

2.5

FUEL STORAGE TANKS, PRODUCT RECOVERY TANKS & DUMP TANKS (EXTERNAL)
Clean, lubricate and visually inspect valves (without dismantling). X MA (Hatch inspection moved to Task 2.55) Visually inspect and check pressure vent valves / vacuum vent valves / combined pressure & vacuum vent valves / general tank vents / flame arrestors to ensure vent and emergency vent passages clear and free to operate. Clean and /or replace filter elements and gauze as required.

2.51

2.52

AS 1940 Clause 9.17 Table 9.1 AS 3873, AS/NZS 3788.

MA

AS1940 table 9.1 requires only visual inspection on a monthly basis, while removal from service and testing is 10 yearly (see Task 2.55)

2.53

Visual inspection of tank fittings, (including floating suction unit winches/anchorages/etc, hatches) ensure secure and gaskets sound

AS 1940 Clause 9.17

MA

2.54

(Task deleted)

(Covered by Task 2.52)

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 1 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D Remove and inspect / test the following equipment : PETROLEUM INSTALLATION (GENERAL) 2.55 a) tank top (Axiom) hatches / gaugers hatches b) pressure vent valves/vacuum vent valves c) manual valves and automatic valves. Visually inspect and test swing arms and floating suction unit to extent possible without entering tank: a) Check for damage and corrosion, b) Check for ease of operation, c) Check float operation by operating float test cable d) Check winch-rope and anchorages e) Check for safe operation of winch. X AS 1940 Clause 9.17 MA W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

Remove vent valves and fittings and check for correct operation. Check pressure/vacuum settings for pressure and vaccum relief valves. Overhaul/replace valves and vents as necessary (Flame arrestor check added to Task 2.52)

2.56

MA

Conduct inspection and tests in conjuction with routine internal tank inspection, or as required if a major issue with swing arms or floating suction units is identified. Refer Task 2.81

2.57

Inspect tank gauging including automatic and manual gauging to ensure correct operation. Check for wear. Test equipment and check calibration. a) direct reading pressure gauge b) differential - Bourdon Tube c) differential - Piston Type

a)

b)

c)

MA

Inspection of internal tank equipment in conjunction with 5Y internal tank inspection. External IAW gauge type.

2.58

Perform visual inspection and testing of level controls, including Low and low-low level alarm / control and high and high-high level alarm / control Check alarm operation. Ensure pump(s) stop, alarm is given and tank valve(s) shut (where applicable) when appropriate level is reached. Rectify faults or repair as required.

AS1940 Table 9.1

MA

Check low level alarm operation when tank is being emptied. Inspection of internal tank equipment in conjunction with an internal tank inspection. Ensure the correct calibration of both the Low and low-low level alarm / control and high and high-high level alarm (Includes tasks from deleted Task 2.76 and Task 3.57)

Identification of coating failure shall trigger the scheduling of reapplication of coating as required. (Internal inspection and NDT requirements merged with Task 2.80.) Externally coated tanks: Inspection and sighting of external coating condition to assess performance and integrity. Check for such things as delamination, bubbling, cracking, peeling, thining, sagging, etc. of coatings.

2.59

MA

Above ground tanks shall be prominently numbered and marked with the fuel grade stored (e.g. F34) and, as a minimum, show the date of the most recent internal inspection and cleaning in accordance with JIG 3 Issue 10 Chapter 3.2.3 (h). In accordance with AS 1940:- 5.2.2 - Markings shall be displayed on the outside walls of the tanks and shall be not less than 500 mm in height for tanks having a diameter of 6 m or greater. For tanks of less than 6 m diameter the markings shall be not less than 150 mm in height.

2.75

FUEL STORAGE TANKS, PRODUCT RECOVERY TANKS & DUMP TANKS (INTERNAL)
(Task deleted) (Covered by task number 2.58) Annual sighting of internal tank condition (silt, protective coating, internal equipment) via a suitable top manhole without draining or entering the tank and paying particular attention to safety of personnel. Note:- on a 5 year basis (not greater than 10 years) the tank may be entered for full survey and maintenance if annual surveys identify the requirement. MA Stainless steel tanks which are not internally coated do not require 3 yearly internal inspections. Identification of coating failure shall prompt an immediate investigation, with the tank removed from service if required, and reapplication of coating scheduled as required (in accordance with Task 2.84)

2.76

2.77

Visual internal tank inspections: a) All tanks: annual sighting of internal tank condition from top manhole b) Internally coated tanks: Tank entry and sighting of internal coating condition to assess performance and integrity. Check for such things as delamination, bubbling, cracking, peeling, thining, sagging, etc. of coatings. Isolate and drain bulk fuel storage tanks prior to 3 yearly tank entry and inspection, paying close attention to confined space entry requirements.

a)

b)

AS 1940; AS 1692; AS 3788; RP12R1; RP575; RP620; RP650; API 653; API 2610; API 2000 and API Spec 12D

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 2 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL)

Tank isolation, draining and inspection of tanks to occur if required by clearly identified degradation of fuel quality. Tank cleaning:Issue 10 Chap 6 Par 6.2.2.3 of the Joint Inspection Group (JIG) states: "No chemicals or cleaning materials shall be used which could be contaminate the aviation product to be stored in the tanks.

Inspection by BFQCO or delegate for the purpose of fuel quality control. Isolate and drain bulk fuel storage tanks prior to inspection (by Operating Agent) paying close attention to confined space entry requirements. Clean if required based on the following: 2.78 a) b) c) d) e) f) a tank inspection warrants; there is an accumulation of solid matter, silt or wax on the tank bottom and fittings; maintenance and repairs are to be undertaken; there is to be a change of product (Consult JFLA in determining cleaning requirements.); the tank is being taken out of commission, or as directed by JFLA tank cleaning requirements. X

DEF(AUST) 5695B. AS 1940; AS 1692; AS 3788; RP12R1; RP575; RP620; RP650; API 653; API 2610; API 2000 and API Spec 12D; Joint Inspection Group - JIG 3; STANAG 3609 Edition 5 annex D; STANAG 3149 Ed 9 annex A and C

Refer to:NAVY/ARMY/AIR NATO Standardization Agreement STANAG 3609 Edition 5 annex D, Guidance for entry, inspection, cleaning and repair of jet fuel storage tanks. NAVY/ARMY/AIR NATO Standardization Agreement (STANAG) 3149 Ed 9 Minimum Quality Surveillance of Petroleum Products. annex A and C A photographic record will be placed in the vessel history file. Note:- on a 5 year basis (not greater than 10 years) the tank may be entered for full survey and maintenance if annual surveys, internal inspections and/or the cleaning process identifies the requirement. Where practicable, other inspections and tests shall be coordinated to occur while tank is empty, e.g. non-destructive testing, inspection of floating suction seals, level controls Periods between tank cleaning shall be no greater: 2 years for Navy storage installations; 3 years for both RAAF and Army storage installations

MA

2.79

Inspect tank internal access ladders for structural defects. Repair as required.

MA

Inspection of internal access ladders in conjunction with an internal tank inspection.

2.80

Examine entire tank (interior) using visual, physical and non-destructive testing techniques for a) estimating the remaining service life; b) verifying the suitability to continue to perform in current conditions as per established tank design criteria or other approved criteria; c) identifying abnormalities; d) protective coating performance and integrity, e) determining structural integrity, wall thicknesses and stability of foundations and, f) providing data for planning repair / replacement.

AS 1940; AS 1692; AS 3788; AS 2312; AS 3873; AS 1692; RP12R1; RP575; RP 579, RP620; RP650; API 653; API 2610; API 2000 and API Spec 12D A typical inspection checklist for Category 4 and 6 tank is given in Appendix B of the BFIMI. Maintenance Agent is to prepare the local inspection checklists suitable for all the related types of tanks in the bulk fuel installations.

MA

Other inspections and tests shall be coordinated to occur while tank is empty, e.g. inspection of floating suction seals, level controls Inspect jointly with OA to discuss problems and defects. A typical inspection checklist for Category 4 and 6 tank is given in the Appendices B1 and B2. The Maintenance Agent is to prepare the local inspection checklists suitable for all the related types of tanks in the bulk fuel installations.

2.81

Perform a physical inspection and test of swing arms and floating suction unit in conjuction with internal tank inspections: a) Check for damage and corrosion, b) Check for fuel in float, c) Check for ease of operation, d) Check winch-rope and anchorages e) Check for safe operation of winch. f) Replace seals in swing arm units as required g) Overhaul / replace / repair unit as required.

MA

Inspection of internal tank equipment in conjunction with an internal tank inspection as directed by JFLA. Industry standards require that after significant internal repair and protective coating repaint/repaint an internal inspection requiring entry will be carried out 12 months after maintenance and then cleaning/full internal inspection with take place at 5 - 10 year intervals depending on condition observed from internal survey of tank and floating suction etc form the top manhole.

2.82

Inspect foot valves and strainers to ensure they are clean and free from sludge, operate freely, and seat and seal.

MA

Inspection of internal tank equipment in conjunction with an internal tank inspection.

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 3 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL) Re-calibration of fuel storage tanks.


2.83 Calibration tables adjusted for configuration of each fuel storage tank must be available at every bulk fuel installation. X API MPMS MA

Calibration required prior to tank entering service. Upon request or on condition. If modifications are made to a tank, which has implications for the tank capacity, it must be re-calibrated as part of the modification procedure.

Repaint tank internal surfaces. JFLA and DSRG - DEMTR are the joint approving agencies for suitable paint schemes. 2.84 Note that whilst AS 2312 is titled as addressing structural steel in atmospheric conditions, it is a sound guide for all protective coating applications and an excellent source of key references X

Written specifications and recommendations of the paint manufacturers. This guidance is critical. Infrastructure Manual (IM). AS 2312 and referenced documents as applicable. Particularly note the guidance available in the appendices.

MA

Internal tank linings/coatings are a specialist item and should not require significant maintenance in the life of the vessel if properly specified, correctly applied and not mechanically damaged during internal tank survey and maintenance access. Any failure or coating breakdown requires a prompt response using a protective coating specialist to identify the root cause of painting system failure and specify rectification coating systems and methods. DSTO PLS MPD provide specialist advice to DSRG - DEMTR

3.50

PIPELINES, VALVES AND COUPLINGS


Hydrant pit couplings and hydrant valves to be maintained IAW manufacturers recommendations. This includes: a) Pit box inspection, checking for water, fuel product; condition of lining, pit lid seal; proper draining if drain lines are fitted; b) Checking valve and components are free from leaks; c) Inspection of operating handle and associated cables / connections; d) Manually determine the integrity of the main valve seal; and, e) Test closure time of valve is between 2 & 5 seconds.

3.51

a) b) c) d)

e)

MA

Items a), b), c) and d) (without deadman) Item e) with deadman)

3.52

Surge alleviators (suppressors): a) Inspect to ensure that surge alleviators are charged with dry nitrogen to 10% less than the line pressure at full flow of the subject pipeline and IAW the manufacturers recommendations to keep shock pressure within acceptable limits. If required, recharge with dry nitrogen. b) Inspect internal condition of pressure cylinder and diaphragm/balloon (depending on design) for corrosion, deterioration and maintain accordingly.

a)

b)

AS 3873, AS/NZS 3788.

MA

Charging and internal survey and maintenance IAW manufacturers recommendations. Internal inspection frequency IAW manufacturere's recommendations or 5 yearly, whichever is less If the device is a registered pressure vessel, a formal PVI and inspection record IAW State Regulations is required.

3.53

Visual inspection of all manual valves, automatic valves, remotely operated valves, air eliminators, automatic drains and pipe fittings for ease of operation, conditions (such as leaks, corrosion and deterioration) and lubrication. Check the integrity of tank inlet and outlet valves, and isolating valves in main lines and ring mains. Clean, inspect and lubricate valves (where required) without major dismantling valve spindles and valves. Use appropriate lubricants. Where valves and/or valve spindles are to be dismantled, WHS and environmental hazards shall be prevented by adequate procedures.

API 570, API RP 574.

OA/MA

Overhaul and/or replace pipelines, valves, couplings and fittings on condition and as required by survey and testing.

3.54

a) Visually inspect pipelines, piping supports, pipe fittings and ancillaries for integrity, and corrosion or mechanical damage. b) Perform thickness measurements using non destructive testing techniques at representative points within the piping circuit

a)

b)

b)

Carry out repairs as required.

AS 2885.3 (applicable to both high and low pressure pipelines for the purpose of this document); AS 3846; API 570; API RP 574.

MA

Inspect jointly with OA to discuss problems and rectification issues prior to OA raising maintenance requests and updating records. Interval between thickness measurements not greater than 10 years. Reduced intervals between thickness measurements may be required based on past reliability of the pipeline, historical records, current knowledge of its condition and the rate of deterioration. MA to assess pipeline, determine required interval, document and obtain approval.

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 4 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL)


Flow meters and flow switches: a) Visual leak and corrosion/deterioration check and lubrication of meters and switches. b) Flow accuracy testing of meters and switches (remove from service, test, and calibrate as required) 3.55 In general, wear of the meter internal rotary components or bearings, as opposed to the calibration mechanism, will effect the low flow test results to a greater degree than at high flow (75% (+/- 5%) of the maximum meter under test (MUT) flow capacity - or at the highest flow rate achievable during normal operating if this is less). a) b) X Maintenance IAW Manufacturers procedures MA Annually or at 100 million litres (whichever comes first), provided the initial error of the meter under test before adjustment is < 0.2% at high flow rate. . Accurate and detailed test and maintenance records are to be kept. DSRG to agree error information description and calculation method. If meter initial error before adjustment is > 0.2% at high flow rate, then the meter and/or its calibration/ adjusting mechanism shall be surveyed and repaired as necessary. (or upon request or condition and IAW local regulations if more stringent)

3.56

Additive injection equipment: a) Examination for operability, leaks. and corrosion/deterioration corrosion and deterioration, and, b) Calibration of the equipment.

a)

b)

IAW Manufacturers recommendations

MA

3.57

Pressure relief valves a) Visual inspection of pressure relief valves b) Test pressure relief valve for correct operation and correct setting. Rectify faults, repair or replace as required.

a)

b)

AS 2885.3 (applicable to both high and low pressure pipelines for the purpose of this document). AS 3873, AS/NZS 3788, AS 3846

MA

MA to generate procedures IAW manufacturers recommendations Calibration and testing IAW with manufacturers recommendations.

3.58

For all automatic control valves, remotely operated valves, pressure reducing/control valves, flow control valves, air eliminators, automatic drains and excess flow valves, perform the following tasks: a) Visual inspection of valves and actuators for leaks, mechanical damage, corrosion. b) Test actuation by remote operation or simulating conditions required for actuation

a)

b)

IAW Manufacturers recommendations and local OA/MA operating instructions.

Particular attention is to be paid to correct functioning of hydraulic, pneumatic or electric driven actuators. MA to generate procedures IAW manufacturers recommendations and local operating instructions, specifying access times which minimise disruption to BFI operations on a 6M and as required basis. Refer also requirements of item 3.53

3.59

Pressure gauges / vacuum gauges (including gauges for shock alleviators (suppressors) For general service gauges: a) Visual inspection for mechanical damage, leaks, gauge operation, dial visibility b) Remove from service and calibrate gauges For gauges associated with filter water separator: c) Visual inspection for mechanical damage, leaks, gauge operation, dial visibility d) Remove from service and calibrate gauges

c)

a) d)

b)

AS 4041

MA

Calibration and testing IAW with manufacturers recommendations. Calibration labels are to be affixed to gauges so tested. Maintenance agent is to retain a register of all gauges, and test and calibration details of each gauge on site at a location agreed by BFQCO. All original calibration and maintenance records and reports to be placed in the facility configuration pressure vessel, valves and fittings register

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 5 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D Leak detection: Monitor pipelines for leaks using the following methods as applicable: PETROLEUM INSTALLATION (GENERAL) a) Survey the route of above ground pipes and inspect for fuel staining, dampness, weeps from screwed and flanged connections and noticeable odours. Inspect the ground around pipes for fuel pooling, staining and dampness b) Survey the route of buried pipes and inspect for a change in the surface contour of the ground, discolouration of the soil, softening of paving ashpalt, pool formation, bubbling water puddles, or noticeable odour. c) For under ground pipe: visually inspect all pits and trenches for leaks d) For double walled pipe: inspect service pits, outer sleeve drains and inspection points for leaks. Monitor interstitial space alarms if installed. e) Check passive leak detection systems such as tell-tales, leak detection wells, etc. f) If electronic leak detection system installed: monitor alarms g) Monitor storm water run-off and interceptor pits for evidence of fuel h) Review the OA's fuel stock reconciliation reports and physically investigate any abnormalities (i.e. if stock levels do not align with fuel received and dispensed, could indicate a potential fuel leak) For above ground pipe: use methods a), e), f), g), h) For under ground / buried pipe: use methods b), c), e), f), g) and h) For double walled pipe: use all applicable methods including d) Pressure (leak) testing: Pressure test the following pipework for the purposes of leak detection and verification of pipeline integrity: i) Pipework supplying an off-shore marine dispenser (i.e. in a marine environment / located above water / located under a wharf) shall be pressure tested to 150% the maximum allowable operating pressure. j) Underground / buried pipework shall be pressure tested to 110% of the maximum allowable operating pressure k) All other pipework shall be pressure tested to 110% of the maximum allowable operating pressure. To the extent possible, a visual inspection of the pressurised pipework shall be performed to detect any leaks. The test pressure shall be held for a period of 8 hours. Four hours after the initial pressurisation of the piping system, the pressure should be noted, and, if necessary, the line repressurised to the original test pressure and isolated from the pressure source. If, during the remainder of the test period, the presure decreases more than 5%, the piping shall be visually inspected externally and/or internally to find the leak. Sonic measurements may be helpful in finding leaks during pressure testing. Pressure tests to be carried out by Maintenance Agent with the assistance of Operating Agent. (Maintenance Agent shall carry out risk assessment for determining safe operating pressure and testing pressure and addressing the limitations of leak/pressure testing. In addition to the limitations of leak/pressure testing past reliability of the pipelines, historical records, current knowledge of its condition and the rate of deterioration (both internal and external corrosion, coating degradation and the like) shall be considered. Also refer to AS 2885 and AS 3846. A written test procedure shall be required to ensure that safety precautions are taken to avoid excessive pressure and fuel spill, and comply with OHS/WHS requirements.) AS 1180 Series; AS 2117; AS 2683; EMEI P009-1 MA to arrange the tests to be carried out using specialist contractors in proper testing facilities with all related WHS procedures in place. All hose specification, survey and testing records are kept on site in the appropriate configuration and maintenance records files. General pipeline checks shall apply to all pipelines, including right of way pipelines, i.e. Task 3.54 a) b) c) d) e) f) g) AS 2885; AS 3846; DEF(AUST) 5695B; MIL-HDBK-1022A; API 570. Maintenance Agent is to develop: h) i) j) k) X a) a marked up drawing of all pipework which splits pipework into testable sections for each installation; and b) a database which records test requirements / results IAW DEF(AUST) 5695, including date of test and due date for the next test. MA to retain information in Configuration & Maintenance Documentation and Records accessible 24/7 to DSO - BMS and HRU & OA. MA If pipeline operating history or thickness measurements indicate the requirement, pressure testing for the purposes of leak detection may be scheduled on an as required basis by the MA. DSO-DC to be consulted. Pressure testing shall be performed following pipeline repair or modification in accordance with AS 4041. Note that when pressure testing lines (leak testing at 110% of design or proof testing at 150% of design IAW AS 4041) care must be paid to isolation of pipe fittings, pressure gauges and metering equipment for example that may not be rated for line testing line pressures. These items will be identified and isolated by blanks as required. Manufacturers/equipment suppliers requirements are to be sought if in any doubt as to pipeline auxiliary equipment capability. MA to check OA fuel dispensing line volume calculations. All tasks may be performed on an as required basis if leaks are reported / suspected or as directed by the BFQCO. W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

3.60

3.61

Hydrostatically pressure test all fuel hoses

OA/MA

3.62

(Task deleted)

3.63

Visual inspection of all external protective coated surfaces such as pipelines, piping and valve supports, pipe fittings, valves and covers a) Check for coating damage, flaking, cracking, corrosion, excessive fading b) Ensure pipe colour codes and labelling is correct c) Repair and repaint as required ensuring all applicable colour codes are retained.

a) b)

c)

c)

AS 1940; AS 2312; AS 2885; Manufacturers recommendations The reference authority is applicable State and Territory legislation.

MA

AS 2312 is the definitive guide for all protective coating applications and an excellent source of key references. Repainting to be performed as required, but at intervals of not more than 10 years.

4.5

FUEL LOADING BOOM, CRANES AND LIFTING APPLIANCES

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 6 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL)


4.51 Perform maintenance routines lubrication and operational checks on the fuel-loading boom and inspect plant that requires plant special license (PSL) IAW the PSL requirements. X X

Manufacturers recommendations, WHS REGULATIONS; PSL requirements: a) SAFETYMAN b) WHSB Guidance

MA

Maintenance routines and operational checks in IAW manufacturers recommendations (minimum requirement) and local maintenance procedures. Annual checks and testing IAW manufacturers recommendations and PSL inspection and testing.

4.52

Perform maintenance routines and operational checks of cranes. Carry out crane load tests. Inspect plant that requires plant special license (PSL) IAW the PSL requirements.

Manufacturers requirements, AS 1418 Series AS 2550 Series. WHS REGULATIONS PSL requirements for original equipment issue/acceptance commissioning: a) SAFETYMAN b) WHSB Guidance.

MA

Maintenance routines and operational checks IAW manufacturers recommendations and the designated Australian Standards together with annual PSL inspection and testing.

4.53

Ensure relevant checks and load tests have been satisfactorily completed for cranes and associated lifting gear such as shackles, slings, etc. is properly stamped/tagged on acceptance for use by the facility with working load limit and test date. Certificated and test/survey records are to be filed/noted in the relevant site register for each equipment item.

Australian Standards for components used in lifting systems. AS 1418 Series, AS 1666.2; AS 1353.2; AS 1380.2; AS 2741; AS 2550.

MA

All lifting appliances and equipment records and certification to comply with relevant Australian Standards when introduced as a new item to site or when recommissioning after major repairs and recorded in the appropriate facility register.

5.5

FILTER WATER SEPARATORS (FWS) , FUEL MONITORS, RELAXATION CHAMBERS AND PUMPS
(Task deleted) Strainer maintenance. Check for leaks, gauze condition, dirt, corrosion, deterioration, and excessive pressure drop, open up monthly and remove and clean as required. (Task deleted) (Task deleted) Inspect/monitor pumps and motors for: a) body and seal leaks, b) excessive vibration/noise and temperature, c) guarding of shafts, d) fans and high temperature items adequate and in good repair, e) fan ventilation clear and clean of debris and dirt and heat sinks (finning) in a clean condition for optimum performance. f) ensure correct installation of safety features such as, bellows/flexibles, guarding g) Check protective coatings, hazard markings and colour coding h) Verify pump function/performance i) Investigate any abnormalities and maintain as required (Covered by task 3.53)

5.51

5.52

MA

5.53 5.54

(Covered by task 3.59) (Covered by task 3.57)

5.55

a) b) c) d) e) f)

g) h)

i)

WHS REGULATIONS AS/NZS 2381 Series. Manufacturers recommendations and sound engineering practice.

This task applies to all pumps, including but not limited to pumps associated with fuel movements, spill containment systems, storm water systems, sumps, waste tanks, etc. MA Respond promptly to any defect/degradation and raise rectification work orders. Note that pump and motor parameters (e.g. suct/disch pressure, flow rate and amps drawn) are key performance indicators of the pumping system and its condition.

5.56

(Task deleted)

Task deleted

Inspect registered plant pressure vessel externally, checking for abnormalities e.g. temperature, pressure, heat, noise or vibrations, and condition of coatings, supports, general alignment of supports, shell, disched ends, welded joints, nozzles, closures and appurtenances. 5.57 If any leakage is detected, further investigations shall be conducted to establish the cause and deleterious effect on the pressure equipment. A certificate or report shall be issued following the inspection in accordance with AS/NZS 3788 X

WHS REGULATIONS AS 3873; AS/NZS 3788.

MA

External inspection covers visual confirmation of the condition of fittings, protective devices, protective coatings, bolting, pressure equipment identification and security of attachments, and the absence of defects, such as corrosion, leaks, bulging, signs of cracking, e.g. at exposed welds particularly those adjacent to supports, excessive dents and integrity of supports and clamps. To be carried out in conjunction with other facility plant & equipment external pressure vessel inspection (PVI) requirements.

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 7 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL)


Inspect registered plant pressure vessel internally. Inspect housing interior for damage, corrosion, condition of lining (for pre-coat units) and presence of cracks within bulkhead welds. Inspect all internal surfaces, including nozzle openings, should be examined for any signs of deformation, discoloration, corrosion, erosion, pitting, cracking, grooving, scale deposits, sludge accumulation, or other defect. 5.58 Indications of reductions in wall thickness shall be verified by supplementary means. X

Where visual examination has highlighted areas requiring a more thorough examination by various non-destructive examination methods, these shall be clearly marked up and reported in the appropriate section of the visual examination report. Testing shall be carried out as outlined in the various non-destructive examination methods described in AS/NZS 3788 Appendix D. AS 3873; AS/NZS 3788. For protective coating inspection and repair, in compliance with paint suppliers' specifications and AS 2312 and its referenced documents and standards is required. Inspection period may be extended if conditions of AS/NZS 3788 Clause 4.4.4.4 are met. MA Internal PVI inspections to be carried out by a competent person. All original inspection, NDT and repair/modification records and reports for an individual vessel and its related fittings to be filed in an individual registered pressure vessel file, as part of the facility PV and PVI configuration records system. Note that whilst AS 2312 is for structural steel protection in atmospheric environments, this standard combined with referenced standards at AS 2312 covers all aspects of protective coating application, inspection, maintenance and repair

Repair any cracks and lining defects discovered IAW procedures submitted to and agreed with the relevant State pressure vessel regulatory authority inspector. Carry out hydrostatic tests after major repairs as agreed with the regulatory authority and good engineering practice. Inspection before closing the vessel should be preformed by a person nominated by the responsible Person (Petroleum).

5.59

Replace FWS coalescer and filter elements if time-expired, exceeding maximum pressure limit or unserviceable, whichever occurs first

DEF(AUST) 5695B and IAW written recommendations of FWS & filter element supplier/manufacturer

MA

2 yearly, and upon request or on condition. Filter replacement to be carried out in conjunction with internal pressure vessel inspection where practicable. Detailed care is to be used when handling and commissioning filters in compliance with suppliers recommendations. OA to assist as required with isolations, etc.

5.60

Repaint filters, pumps, air eliminators, strainer, supports and covers. Ensure applicable petroleum product colour codes and marking are retained.

MA

Upon request or on condition, but at intervals not greater than 10 years

5.61

(Task deleted)

(Covered by Task 5.59)

6.5

FUEL SAMPLING
Check fuel sampling systems, for leaks, damage and unserviceable equipment X X Manufacturers recommendations MA A maintenance register of work requested and completed on any equipment dedicated to fuel sampling and testing is to be maintained as part of the documentation and configuration responsibilities of the MA

6.51

7.5

ELECTRICAL INSTALLATION, CONTROLS, BONDING AND EARTHING


WHS REGULATIONS AS 3000, AS/NZS 4761 DIM requirements. The test for operation shall ensure that the RCD operates within the maximum tripping times and current levels as required by: AS 3190; AS/NZS 61008.1 or, AS/NZS 61009.1. Earth leakage tests to be logged, any defects to be rectified immediately or circuits tagged out until repair or a portable device connected as an interim solution. MA to ensure RCD numbers and type comply with AS and DIM requirements and are tested by a competent person. Survey and test records to be developed and maintained as part of the Configuration and Maintenance records. (Combined with Task 7.56.)

7.51

Residual current device (RCD) survey and testing a) push button b) test for tripping operation of with a specialist tester IAW AS requirements

a)

b)

MA

7.52

Bonding/earthing cables, clips, plugs and reels including Scully type connectors where associated with the fixed installation and not associated with those provided on vehicles. Inspect for physical damage and perform continuity testing. Scully type connections shall include testing continuity through to a tanker vehicle.

AS/NZS 3000; AS /NZS 1020; AS 1076; DEF(AUST) 5695B; AS/NZS 4761.

MA

Particular attention to be paid to addressing the maintenance and testing requirements at sections 5 through 7 of AS 3000

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 8 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL)

7.53

Carry out inspection of earth reference points. Stencil new test date.

AS /NZS 1020 (Sect 23); AS/NZS 3000; AS/NZS 4761; AS 2381. The requirements of all quoted standards are supplementary to AS/NZS 3000 and not alternative to any of AS/NZS 3000 requirements. Defence requires that all maintainers will notify the relevant technical authority with written justification where the informative directions of these standards are disregarded. AS /NZS 1020 AS 3000, AS/NZS 4761 The requirements of all quoted standards are supplementary to AS/NZS 3000 and not alternative to any of AS/NZS 3000 requirements. Defence requires that all maintainers will notify the relevant technical authority with written justification where the informative directions of these standards are disregarded

MA

Resistance measurements are to be recorded and trended in an appropriate document.

7.54

Check bonding, protective conductors, antennae earthing, earthing stakes and earthing cables, clips, plugs and reels for continuity in association with those provided on vehicles

MA

Continuity results to be recorded and trended in an appropriate document.

7.55

Visual inspection. Inspection of the complete electrical installation and confirmation that the installation is free of mechanical failure, corrosion, general damage and overheating. Ensure and record that: a) No unauthorised modifications have been made to the installation or fixed appliances and they are in a safe and satisfactory condition for continued operation b) The installation, apparatus and fixed appliances comply with the documentation, and that any special installation conditions have been adhered to c) All equipment labels and markings are legible, the equipment is correctly assembled, and all fixings (bolts and nuts) are present d) The enclosures, glasses, glass/metal seals of the lights are satisfactory and the lamp types and ratings are correct e) There is no evidence of compound from stopper or cable boxes and there is no obvious damage to cables f) Flexible cables show no signs of damage deterioration, sun damage or overheating and are mechanically secured to the apparatus in accordance with the installation documentation g) There is no undue accumulation of dust and dirt and equipment is adequately protected from weather h) The installation and the associated equipment and fixed appliances function correctly i) Records of inspections, checks and tests at the prescribed intervals have been kept and the installation conforms with the records j) Inspect zone rated electrical boxes to ensure correct sealing. Check for evidence of warping of box lids due to sun exposure. Where warping is identified the box shall be flagged for replacement and DEMTR contacted for advice. k) Inspect exposed cables for condition, mechanical and UV sunlight damage. Flag damaged cable for replacement. If UV damaged cable is identified, the use of covered cable trays should be considered.

AS/NZS 3000; AS /NZS 1020; AS 1940; AS 1692; API RP 2003; AS/NZS 1768; AS 2380 Series; AS/NZS 2381 series; AS/NZS 60079.10.1; AS/NZS 3800; AS/NZS 3947 Series; AS/NZS 60079 Series; AS/NZS 4761. The requirements of all quoted standards are supplementary to AS/NZS 3000 and not alternative to any of AS/NZS 3000 requirements. Defence requires that all maintainers will notify the relevant technical authority with written justification where the informative directions of these standards are disregarded.

MA

To be coincident where possible with access for other maintenance activity such as lightning protection inspections or bonding cable testing etc.

7.56

(Task deleted)

combined with task7.51

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 9 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL)

7.57

Close & Detailed inspection. Check that the condition and operation off the electrical equipment and apparatus incorporated in the installation. Specific attention should be given to the following: a) Damage to the enclosure and the enclosure finishes b) Damage and/or deterioration of insulation of components and accessories within the enclosures c) Damage and/or deterioration of the insulating materials and insulating barriers within the enclosures d) Security of access doors and the condition of any gaskets on the access doors and panels e) Corrosion, overheating and tightness of connections f) Corrosion, overheating and pitting of contacts g) Satisfactory operation of electrical and/or electrical interlocks h) Satisfactory operation of contactors, relays, switches and other components i) The correct current rating of fuses and circuit breakers j) The correct operation of instruments, meters, indicator lights, alarm and test devices k) The integrity of locks and/or seals on meters, fuses and special equipment I) Correct operation of trip switches, emergency stop switches/push buttons and similar safety devices m) Optical pyrometry of switchboards and starters

AS/NZS 3000, AS /NZS 1020 AS 1940, AS 1692, API RP 2003, AS/NZS 1768, AS 2380 Series, AS/NZS 2381 series, AS/NZS 60079.10.1, AS/NZS60079.17:2009 AS/NZS 3800, AS/NZS 3947 Series, AS/NZS 60079 Series, AS/NZS 4761 The requirements of all quoted standards are supplementary to AS/NZS 3000 and not alternative to any of AS/NZS 3000 requirements. Defence requires that all maintainers will notify the relevant technical authority with written justification where the informative directions of these standards are disregarded.

With respect to the inspection frequency AR- AS/NZ60079.17, clause 4.4.2 applies for the determination of an appreciate inspection interval. To be coincident where possible with access for other maintenance activity such as lightning protection inspections or bonding cable testing etc. The referenced Australian Standards are the basis for al electrical work quality and activity associated with Defence BFIs. Particular attention to be paid to addressing the maintenance and testing requirements at sections 5 through 7 of AS 3000. Switchboards and local starter boxes should be examined using thermography as part of inspecting process. To predict accurately an appropriate periodic inspection interval is a complex issue. The grade of inspection and the interval between periodic inspections shall be determined taking account of the type of equipment, manufacturer's guidance, if any, the factors governing its deterioration (see Note 2 to 4.3.1), the area classification and/or the EPL requirements and the results of previous inspections. Where inspection grades and intervals have been established for similar equipment, plants and environments, this experience shall be used in determining the inspection strategy.

MA

7.58

Functional check of all safety systems and alarms where not covered by specific checks elsewhere in this schedule (e.g. bund and separator high level alarms, general emergency alarms and beacons).

Manufacturers recommendations and MA designed procedures for testing and proving in a hazardous area. AS 31000 MA/OA Manual of Infrastructure Engineering Electrical

MA to generate a facility specific procedure checklist addressing the methodology and detailed requirements for functional alarm and trip testing. and record on file as part of the configuration document dossier. The functional testing will require process variations to validate the circuit to loop and this will need specialist OA assistance

7.59

Testing of mobile generator set link boxes

AS 3000, Manufacturers recommendations, AS 2381

MA/OA

Where fitted - OA assistance may be required

7.60

Check electrical safety signs, labels, notices and posters fixed on or adjacent to electrical equipment and appliances are: a) Securely fixed b) Clearly readable at normal operating or maintenance positions and correctly identify the equipment or appliance and/or its purpose c) In accordance with AS 3000, d) are fitted at the point of connection of every earthing conductor and earth electrode, the main equipotential bonding and the points of connection of every bonding conductor to extraneous conductive part e) Prominently displayed as specified in local facility safety rules and procedures

AS 3000; AS 3800; AS/NZS 60079.10.1; AS 1319; AS 1470; AS/NZS 4761.

MA

A schedule/drawing detailing type and location of all safety and operational signage is to be maintained by the MA addressing: a) electrical, b) personal safety, c) access, d) hazard identification, e) personal protection, f) instructional, g) security and h) advisory

7.61

Lighting. Inspect and test to ensure that lights are working, light covers are clean / not sun damaged / faded yellow / clear of dead insects etc., movement and light level sensors operate correctly.

AS/NZS 1680 Series, AS/NZS 2293 Series, AS/NZS 1158 Series, AS/NZS 4761, Other relevant Australian standards, Commonwealth/State/Territory Legislation and Regulations and Manufacturers recommendations.

MA

7.62

Repair/replace bonding and earthing cables, clips, plugs and reels in association with those provided on vehicles

AS/NZS 4761

MA

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 10 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL)


Lightning protection systems: a) Inspect after alteration or extension in order to verify compliance with AS/NZS 1768. b) Routine inspection of all system components including conductors, poles, bonds and joints checking their mechanical condition and looking for weathering damage, corrosion, and stroke damage. Tighten as required all accessible clamps and splices c) Measure and record the resistance to earth of the whole installation, including each earth termination, to verify the electrical continuity of all conductors, bonds and joints.

Where regular testing during maintenance reveals that the earthing resistance is substantially unchanged, the frequency of maintenance testing may be reduced to every 4 years. Physical inspections are still required on a 2 yearly basis. Records must be maintained of earth resistance testing with the following information: test conditions, date, results, the nature of the soil and any special earthing arrangements. If the resistance to earth of the LPS exceeds the specified value for the particular application, repairs or alterations should be conducted to reduce the value to be in accordance with AS/NZS 1768. (New Task)

7.63

b) c)

a)

AS/NZS 1768

MA

7.64

Cable trays: Inspect cable trays to ensure they are well supported, cables are contained within the tray, tray lids are in place and secured, and that there is no corrosion / coating failure / mechanical damage.

MA

(New Task) The MA shall maintain the Hazardous Area Verification Dossier in accordance with the following documents, the Manual of Infrastructure Engineering - Bulk Fuel Installation Design, and the Manual of Infrastructure Engineering Electrical (both available at http://www.defence.gov.au/IM/) and AS/NZS 2381.1.

7.65

Maintain and update the Hazardous Area Verification Dossier as required after any repairs, modifications, upgrades, change of electrical equipment, etc.

AS/NZS 2381.1; AS/NZS 60079.10 Manual of Infrastructure Engineering - Electrical

MA

If the Hazardous Area Verification Dossier is found to be non-compliant with the existing installation, the MA shall communicate this to DSO-RD for follow up. (New Task)

8.5

CATHODIC PROTECTION

8.51

Maintenance of cathodic protection equipment. Cathodic protection equipment shall be maintained in accordance with the manufacturers/installers recommendations. This shall include: a) check power source for supply b) inspect rectifier/anodes for any signs of damage c) record voltage and ampere measurements d) undertake potential measurement survey e) train the OA in understanding the system, its operation and recording requirements

a) b) c)

d)

e)

AS 2239; AS 2832 Series; AS/NZS 4761. Provide operating criteria and training to OA for carrying out regular recording of current and voltage in impressed current systems as required in the standards and manufacturer's / supplier's recommendations.

MA

The Maintenance Agent shall engage a specialist in cathodic protection to inspect and carry out a survey of the cathodic protection systems and determine the most appropriate maintenance intervals. The MA is also responsible for training the OA to a level where the OA is competent in understanding the design, operation and recording requirements of the facility cathodic protection systems in the relevant dossier in the configuration and maintenance files

9.50

LOCAL EMERGENCY GENERATOR (LEG)


AS/NZS 3009 (Appendix B) for the purpose of this schedule and any relevant Infrastructure Manual LEG requirements (available from Defence website).

9.51

Test operation of the LEG

MA/OA

Prior to shutdown, after the machine temperatures have stabilised on load, all key readouts to be recorded - any defects in equipment, instruments or controls to be rectified.

9.52

Maintenance

In accordance with the manufacturers requirements and any relevant Infrastructure Manual LEG requirements (available from Defence website).

MA

Routine maintenance and testing to be detailed in the MA maintenance plan based on manufacturers recommendations and good engineering practice.

10.5

FIRE FIGHTING PROTECTION SYSTEMS, FIRST AID, AND WHS

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 11 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL)

10.51

Maintain all fire equipment. (Competent persons to be used at all times)

AS 1940; Defence Guidelines MFPE; AS 2293 Part 2 - Maintenance and Testing of Emergency Evacuation Lighting in Buildings; NFPA Code No 11 - Low Expansion Foam and Combined Agent System - Maintenance; AS 1851-2005 Maintenance of Fire protection Systems and Equipment - series.

MA

MA to produce testing and maintenance schedules and location drawing of all fire fighting systems and equipment IAW the references. A sound summary is available in the annexes to Ch15 of DIM MFPE. The schedule to be broken down into functional groupings IAW AS 1851 and detailed history sheets addressing specification. location and checks & maintenance to be recorded by MA in the configuration and maintenance files. Minimum maintenance and survey/testing schedules to be in accordance with AS 1851 frequencies or better. All equipment to be tagged and specification and testing recorded in the relevant configuration and maintenance documentation files.

10.52

Inspect and test deadman control devices for correct operation and setting.

Manufacturers recommendations.

MA

Monthly, and upon request or on condition.

Check emergency safety showers and eye-wash stations to: a) rectify problems such as valve leakage, clogged openings and pipelines, and adequacy of the fluid volume; and b) carry out complete inspection including functionality, adequate flow and pressure, and correct operation of associated alarms and shut-down systems. c) ensure safe and unobstructed access d) ensure exposed water supply pipework is insulated to prevent heat build-up AS 4775 Manufacturers recommendations, DIM (Department of Defence Emergency Eyewash and Shower Station Policy)

10.53

MA

10.54

Check and replenish water and foam Tanks.

Defence Guideline MFPE

MA

Testing of AFFF is to be carried out annually. Any deficiency identified by laboratory testing requires replacement of AFFF.

Test and maintain fire protecting pump set systems and compression ignition engines (diesel generators where applicable). Inspect/monitor pumps and motors for: a) body and seal leaks, b) excessive vibration/noise and temperature, c) guarding of shafts, d) fans and high temperature items adequate and in good repair, e) fan ventilation clear and clean of debris and dirt and heat sinks (finning) in a clean condition for optimum performance. f) ensure correct installation of safety features such as pressure relief, bellows/flexibles, guarding g) Check protective coatings, hazard markings and colour coding a) b) c) d) e) f)

10.55

g)

Maintain in accordance with AS 1851 manufacturer's instructions and relevant sections of the DIM (LEG)

MA

MA to ensure accurate test results are taken by the OA and forwarded for inclusion in Configuration and Maintenance documentation files. MA should accompany the OA at least monthly to observe OA equipment testing and checks

11.5

VENTILATION SYSTEMS
Inspection and maintenance of ventilation systems including fans, motors, air filters, outdoor air intake, exhaust and safety shut down.

11.51 Ensure filters, vents and louvres are clear and not obstructed with dust/dirt build up. Clean / replace as required.

AS 1851.6 for the purpose of this schedule; AS 2381 Series; AIRAH - DA19.

MA

Maintenance and survey records to be maintained by MA

12.5

COMPRESSED AIR SYSTEMS


Perform visual inspection of all compressed air systems including a) Compressors, dryers and other plant b) Pipelines, valves, hoses and associated connections, pressure regulators, pipe and equipment supports. c) Maintain, lubricate and repair as required.

12.51

a)

b)

c)

AS 4297 for the purpose of this schedule; AS 3873; AS/NZS 3788.

MA

12.52

For air operated diaphragm pumps, check and replenish lube oil.

Manufacturers Instructions

MA

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 12 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL) Inspect plant (air receiver) externally, checking for abnormalities e.g. temperature, pressure, heat,
noise or vibrations, and condition of coatings, supports, general alignment of supports, shell, disched ends, welded joints, nozzles, closures and appurtenances. 12.53 If any leakage is detected, further investigations shall be conducted to establish the cause and deleterious effect on the pressure equipment. A certificate or report shall be issued following the inspection in accordance with AS/NZS 3788. X AS 3873; AS/NZS 3788. Written specifications of the paint manufacturers. DIM External inspection covers visual confirmation of the condition of fittings, protective devices, protective coatings, bolting, pressure equipment identification and security of attachments, and the absence of defects, such as corrosion, leaks, buldging, signs of cracking, e.g. at exposed welds particularly those adjacent to supports, excessive dents and integrity of supports and clamps. (Internal inspection requirements moved to Task 12.54.)

MA

Inspect registered plant pressure vessel internally. Inspect housing interior for damage, corrosion, condition of lining (for pre-coat units) and presence of cracks within bulkhead welds. Inspect all internal surfaces, including nozzle openings, which should be examined for any signs of deformation, discoloration, corrosion, erosion, pitting, cracking, grooving, scale deposits, sludge accumulation, or other defect. 12.54 Indications of reductions in wall thickness shall be verified by supplementary means. Repair any cracks and lining defects discovered IAW procedures submitted to and agreed with the relevant State pressure vessel regulatory authority inspector. Carry out hydrostatic tests after major repairs as agreed with the regulatory authority and good engineering practice. Inspection before closing the vessel should be preformed by a person nominated by the responsible Person (Petroleum). X AS 3873; AS/NZS 3788. MA

Where visual examination has highlighted areas requiring a more thorough examination by various non-destructive examination methods, these shall be clearly marked up and reported in the appropriate section of the visual examination report. Testing shall be carried out as outlined in the various non-destructive examination methods described in AS/NZS 3788 Appendix D. Inspection period may be extended if requirements of AS/NZS 3788 Clause 4.4.4.4 are met. Internal PVI inspections to be carried out by a competent person. All original inspection, NDT and repair/modification records and reports for an individual vessel and its related fittings to be filed in an individual registered pressure vessel file, as part of the facility PV and PVI configuration records system. Note that whilst AS 2312 is for structural steel protection in atmospheric environments, this standard combined with referenced standards at AS 2312 covers all aspects of protective coating application, inspection, maintenance and repair. (New Task, previously covered by Task 12.53)

13.5

ENVIRONMENTAL
(Task deleted) (Covered by audit function of BFIMI)

13.51

13.52

Perform visual inspection of gauges and level alarms in fuel/wateroil interceptors, retention ponds, retention pits and dump tanks for spill retention

MA

Instruments in environmental service require the same standard of integrity and maintenance as in other parts of a bulk fuel installation.

13.53

Inspect bunds and associated spill containment systems. Ensure general serviceability, no damage, no leakage and no corrosion. Repair joints, cracks and damage to walls and floor as required. Inspect and replace damaged / ineffective / dislodged joint sealing compounds with the most suitable materials and processes. Remove and dispose waste fuel and contaminants as required.

AS 2865; AS1940; EPA Victoria Publication 347 or similar publication from an equivalent Commonwealth/State/Territory agency. Base-specific Waste Disposal Agreement as per Base EMP

MA

13.54

Inspect oily/water systems. a) The systems include fuel/oil interceptors, fuel/oil separators, retention ponds, retention pits, and dump tanks for retention purpose. b) Ensure general serviceability, no damage, no leakage and no corrosion. c) Check functionality. d) Clean and repair as required. e) Remove waste fuel and contaminants as required. Inspect retention ponds and pits f) Inspect and replace damaged / ineffective / dislodged joint sealing compounds with the most suitable materials and processes.

AS 2865, Base-specific Waste Disposal Agreement as per Base EMP, and Base-specific Trade Waste Agreement as per Base EMP

MA/OA

Coordinate with OA monthly inspection of drains and related fittings. Competent OA as Standby Person under confined space entry Safety Control Certificate. May relax frequency first to 3M and later to 6M after one year (each) if monitoring is found to be too frequent on a Base-specific basis.

Report any inadequacy associated with fuel/oil interception, separation and/or retention process; or infrastructure of the oily/water systems; or both with appropriate mitigation plans.

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 13 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION Inspect and test leak monitoring/ detection (GENERAL) equipment for satisfactory operation including:
13.55 a) b) c) d) e) f) g) tank dipsticks (straight, legible, not worn) photo-ionisation Detector flammable Gas Detector line Leak Detector ground Water Bailer water Sensitive Paste check calibration. (b) (c) (d) a)

Instrument Tests shall comply with the Statistical Inventory Analysis System standards and certified to USEPA/530/UST-90/007 (system supplier standard), (e) AS 4897; (f) AS 4482.2; AS/NZS 61779.4. IAW Manufacturers Recommendations API Publication 334.

MA

Gas detection equipment checks and calibration to be carried out quarterly and certified test records maintained in the relevant file in the configuration and maintenance records. Replace water sensitive paste if condition deteriorates or in accordance with manufacturer's use-by date.

Monitoring of the interstitial space of double-walled underground tanks or pipeline to: Check for evidence of fuel leaks, fuel vapours, water. Ensure liquid levels and pressures are IAW manufacturers specified limits. 13.56 Report to DSO-BSM for referral to DSO - SEM promptly when leakage is detected. DSO - SEM will decide appropriate follow up actions and the need for further monitoring. Record the results and kept them on site in a suitable location. X X AS 4897 Commonwealth/State/Territory Legislation and Regulations Base EMP Manufacturer's recommendations and requirements If required in EMP: a) to comply with AS 4897 and Commonwealth/ State/Territory Legislation and Regulations, or b) 6 monthly, whichever is the shorter interval. Upon request or on condition.

MA

13.57

Inspect Groundwater/Soil Air Monitoring Bores, Tank Pit Observation Wells used for leak detection purposes and ensure they are: a) clearly marked and secured b) sealed at ground surface c) documented in configuration records. d) free of fuel leaks. Report to DSO-BSM for referral to DSO - SEM promptly when leakage is detected. DSO - SEM will decide appropriate follow up actions and the need for further monitoring. Record the results and kept them on site in a suitable location.

AS 4897 AS/NZS 5667.11 Commonwealth/State/Territory Legislation and Regulations Base EMP

MA

13.58

Respond to environmental maintenance requirements as required.

AS/NZS ISO 14015

MA

Removal of failed equipment should be at the discretion of the investigating authority.

13.59

Clean dump tanks and remove sludge.

AS 2865 Base EMP: Base-specific Waste Disposal Agreement Base-specific Trade Waste Agreement

MA

13.60

Clean drains. Ensure no blockages. Repair covers as required.

AS 2865

MA

13.61

Assessment of adequacy of containment arrangement for any minor or major leaks and spills. Assessment is required when there is: a) no record of updated assessment that verifies adequacy; b) change in operational conditions; or c) change in related legislation & regulations.

AS 1940 AS/NZS 31000 Base EMP SAFETYMAN

MA

Contributes to periodic review of Base EMP as element of Hazard and Risk Review.

13.62

Audit fuel storage tanks and pipework and report any potential environmental risks associated with the tank installation.

AS 1940 Base EMP SAFETYMAN Vol 1 Part 1 Chapter 7

MA

In conjunction with internal tank inspection, and upon request or on condition. Contributes to periodic review of BASE EMP as element of Hazard and Risk Review.

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 14 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM INSTALLATION (GENERAL)


DISCREPANCY/LOSS INVESTIGATION DATA VALIDATION Assist Operating Agent in fuel Discrepancy/Loss investigation and determine whether discrepancy or loss is: a) significantly in excess of normal pattern. In this event, activate step (2) within TWO DAYS b) higher than normal but not significantly in excess of normal pattern. In this event, activate step (2) within 10 DAYS 13.63 Discrepancy/Loss Investigation Procedure to (validate data used to identify loss will include: a) check correct configuration of tank, meter alignment used to reconcile data b) check dipstick IAW this Instruction c) check calibration of meters/weighbridges used for data reconciliation IAW this Instruction or make enquiry re-calibration to weighbridge operator d) confirm that fill points and dipstick ports are correctly sealed. Report whether data is validated and recommend Equipment Integrity Test IAW this instruction as appropriate X AS 4897; API 334 Instrument Tests shall comply with the Statistical Inventory Analysis System standards and certified to USEPA/530/UST-90/007 (system supplier standard), Commonwealth/State/Territory Legislation and Regulations,

MA

DISCREPANCY/LOSS INVESTIGATION EQUIPMENT INTEGRITY TEST Equipment integrity test of Underground Petroleum Storage Systems (UPSS) and Above Ground Petroleum Storage Systems including leak test of tanks as part of Discrepancy/Loss Investigation To be carried out by competent and experienced persons. 13.64 UPSS include underground petroleum storage tanks, product recovery tanks, dump tanks and wastewater holding tanks and their associated piping/fittings.. The Maintenance Agent is to retain a register of test results of each system/tank in Configuration and Maintenance Documentation and Record system and available 24/7 to DSO-BSM and BFQCO. X

AS 4897 (Appendix D), Commonwealth/State/Territory Legislation and Regulations, For discrepancy loss investigation, the secondary confirmation must be by a method independent of the primary detection method, but compliant with AS 4897 and USEPA/530/UST-90/007

MA

Physical integrity inspections to be carried out in conjunction with an internal tank inspection where practical.

Repair cracks in Inspect concrete pads at offloading points, dispensing points, pumps, and filter water separators and truck shelters. 13.65 Inspect and replace damaged / ineffective / dislodged joint sealing compounds with new and most suitable petroleum / gas / acid / UV resistant jointing compounds available. X MA

13.66

LEAK OR SPILL RESPONSE Assist as requested with the conduct of environmental site assessment or other investigations as appropriate. Request may be initiated following: a) confirmation of leak, requiring a leak or spill response or b) identification of signs of fuel leaks are shown in ground (including soil and vegetation above buried pipelines and tanks, and in the vicinity of aboveground pipelines and tanks.)

AS 4897 Commonwealth/State/Territory Legislation and Regulations Requirements of EMP

MA

Under direction of DSO - SEM

13.67

Bund integrity testing.

IAW industry practice and, AS 1940.

MA

Specific testing must be planned with reference to Configuration Documentation to identify construction details such as membranes as specified by DSRG DEMTR/DSRG - DEEP and directed by DSO - SEM

13.68

Inspect spill kits (e.g. wheelie bin type) and other spill containment equipment (booms, etc.) for condition, completeness and correct signage and labelling.

MA

(New Task)

14

DOCUMENTATION
Check that current MSDSs are held of all products and chemicals/solvents used at the BFI X WHS REGULATIONS OA

14.01

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 15 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

PETROLEUM Asbestos. INSTALLATION (GENERAL)


14.02 Check Asbestos Hazard Register. For all facilities, ensure the OA holds and maintains a current copy of the Asbestos Hazard Register. (Work to be carried out by Maintenance Agent and supervised by BFQCO.) When there is a handover of Maintenance Agent, an updated copy of the Register is to be handed over in a proper manner. X WHS REGULATIONS DSO SEM Asbestos removal is a specialist task only to be undertaken by suitably competent and approved removalists. NOHSC:2002 refers. The OA is to hold and maintain a current copy of the Asbestos Register.

14.03

Asbestos For all facilities, maintain the Asbestos Hazard Register. When there is a handover of Maintenance Agent, an updated copy of the Register will need to be handed over to the MA in a proper manner.

DI(G)PERS 40-1 IM

OA

Upon request or on condition.

14.04

Review maintenance records for fuel farms. Ensure the records are accurate and conform to IAW DEF(AUST)5695B and the requirements of this instruction. Log books/maintenance records/configuration documentation are to indicate that this review has occurred. Check that all information and results of tests and calibration are kept on site and accessible as required by this Instruction and BFQCO and CSM.

WHS REGULATIONS

DSO SEM

14.05

Review and amend emergency response plans. Ensure that the plans that deal with fuel spill and fire in the fuel compound and other similar scenarios are accurate and suitable. Upon completion of this review, a copy is to be forwarded to JFLA for information and archiving. (Work to be carried out by BFQCO)

WHS REGULATIONS

OA

14.06

Ensure storage, handling and disposal of waste fuels or contaminants (fuel/water/cleaning fluids) is IAW local procedures, Commonwealth/State/Territory Legislation and Regulations and the requirements of this Instruction.

WHS REGULATIONS

OA

14.07

Configuration Control Check all equipment against the sites detailed equipment lists. Ensure: a) The list accurately reflects the physical site, b) No unauthorised configuration changes have taken place. c) No equipment is missing or incorrectly placed. Any problems discovered during this check are to be reported immediately to JFLA, if the facilities capability is affected. (Work to be carried out by BFQCO)

MA

14.08

General Storage, handling and disposal of waste fuels or contaminants (fuel/water/cleaning fluids) is in accordance with the requirements of this Instruction.

DSO SEM

(Work to be carried out by Maintenance Agent and supervised by BFQCO)

14.09

Check that a record of completion of all maintenance services carried out is maintained and cross referenced to relevant permit to work (which includes personal accreditation reference) and related documentation..

DSO SEM

15

COMMUNICATIONS
(Task moved to OA Task 15.01) (Task moved to OA Task 15.02) Check that radio receiving antennae and other metal structures that may act as receivers are earthed. AS 3846, ISGOTT

15.01 15.02

15.03

15.04

Ensure that portable radios can satisfactorily transmit and receive from all areas of the BFI facility and wharfage

HB 13, AS 2381 AS 3846

All communication equipment is to be certified for hazardous zone use. Battery chargers with their control equipment and batteries being charged are not permitted in a hazardous area, unless such equipment is suitable for the hazardous area.

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 16 of 17

Maintenance Requirements for Defence Bulk Fuel Installation Facilities Maintenance Schedule - Maintenance Agent (MA) Tasks - Technical
Servicing Frequency Task No Task D W 2W M 3M 6M A 2Y 3Y 4Y 5Y 10Y AR Reference/Authority Resp Checked DEMS Record Remarks

Notes:

PETROLEUM INSTALLATION (GENERAL)

a) Authorisation for repairs / overhaul / replacement shall be in accordance with the Maintenance Contract. b) All the publications referred to in this Schedule shall be the latest edition, including amendments. c) The title of each publication is in appendix H . d) These annexed maintenance procedures are not exhaustive and should be used as guidance only. Individual BFI facilities will be required to amend these procedures to reflect their unique asset configuration and environmental requirements. These modifications should be reflected in each BFI facility maintenance plan. e) OA - Operating Agent f) MA - Maintenance Agent g) Resp. - Responsibility h) AR - as required i) D - Daily: W - Weekly: A-Annually: Y- Yearly j) JFIMS - Joint Fuel Information Management System

Definitions (in accordance with AS1940 Table 9.1 for tank inspections) Visual inspection refers to a visual examination of the equipment without removal from service Physical inspection refers to a visual inspection and appropriate tests to confirm the function and condition of the parts and identify any weakness, deterioration or faults To be printed on A3 sheet.

Appendix A1 - BFIMI Maintenance Schedule - MA Version 2.0 - July 2013

Page 17 of 17