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Chapter 10PETROLEUM PIPELINES AND STORAGEFACILITIES

T he AirLand battlef ield is a highly mechanized and mobileenvironment, increasingly dependent on petroleum products,In t he European Theater dur ing World War II, a bout ha lf the tota llogistical tonnage was petroleum fuels. During the Korean Warand in the war in Vietnam, this figure rose to about 60 percent.The concept of mobile warfare on the deep battlefield of futureconflicts anticipates increased consumption of these products,

In the conceptual plan for supplying needed fuels. hulk petroleumis delivered through ports or LOTS. There, it is off-loaded intostorage facilities and sbipped forward. The modes of shipment indescending order of priority are pipeline, inland waterways, rail,motor carriers, and aircraft. The preferred method of shipment tothe corps area is by pipeline. The use of pipelines reduces theamount of traffic on other modes of transportation. Pipelinessave more energy and personnel costs than other methods ofoperation. The Engineer mission is to provide genera] andspecia l ized ass is tance in bui lding and mainta ining pipel inesystems.

RESPONSIBILITIES 86

ENGINEER CAPABILITIES 87

MILITARY BULK PETROLEUM DISTRIBUTION SYSTEMS 88

PIPELINE CONSTRUCTION AND MAINTENANCE 90

PETROLEUM PIPELINES AND STORAGE FACILITIES 85

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responsible for all aspects of theater levelpetroleum distributio planning and relatedsupply opeations. The group performs liai-son with the Theater Army Materiel Manage-ment Center (TAMMC) and Host Nation(HN) staffs for coordinating allied petroleumdistribution support. I t dist ributes fuels based

RESPONSIBILITIES

The J oint P etroleum Office (J P O) coordina tes on priori t ies establ ishedthe petroleum needs of a ll services w ithin t he mander and by directivesTh ea t e r com m a n d. Th e pet r oleu m g rou p TAM MC .commander for the Theater Army (TA) is

by the TA com-received from the

Bulk petroleum in the Theather of Operationsis distributed by the Petroleum Pipeline andTermina l Opera t ing Ba t ta l ions . These ba t-talions are responsible for the operation ando r g a n i z a t i o n a l m a i n t e n a n c e o f p e t r o l e u mpeipel ines and s torage fac i l i t ies . They areresponsible for instal l ing col lapsible tanks

86 PETROLEUM PIPELINES AND STORAGE FACILITIES

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and associated equipment for the Tactical ENCOM provides maintenance (excludingP e t r ol eu m Ter m in a l (TP T). Th ey a ls o i ns t a ll or g a n i z a t i o n a l m a i n t e n a n ce ) a n d r e pa i r o fcol la p s i bl e h os e li n es u s ed t o t e m p or a r i l y ex is t in g p ipe li nes . I t a l so d es ig n s, con s t ru ct s ,ext end pipelines. a n d expa n ds t h e t a ct ica l pipelin e sy st em

( inc lud ing mar ine termina ls and s torageTh e Th e a t e r Ar m y E n g i n e e r C o m m a n d fa cilit ies). Th ese t a sks a r e d on e by U S en gi-(ENCOM) or the senior engineer HQ suppor ts neer forces or through coord ina t ion wi th thet h e p et r ol e u m d is t r ib u t i on ef f or t . Th e H N.

ENGINEER CAPABILITIES

Engineer support to the petroleum distribu-tion effort calls for a combination of generaland special construction skills. To maximizepotential and minimize duplication of lowdensity skills and equipment, general engi-neer construction units are augmented withspecialized units from the active or reservees tab l i shments .

COMBAT HEAVY ENGINEERBATTALIONS (TOE 5-115)

The primary military engineer units requiredto support the petroleum distribution effortare the Combat Heavy Engineer Bat ta l ions.These units provide horizontal and generalconstruction support for most of the tacticalpipeline construction mission.

Many tasks in pipeline construction are hori-zontal . These include route c learing andf l a t ten ing , and cons t ruc t ing gap c ross ingsand pipe supports. These tasks can best bedone by a genera l cons t ruc t ion uni t w i thheavy earthmoving equipment. The battal-ions also provide the labor or help to super-vise HN personnel for assembling pipe andassociated equipment.

ENGINEER PIPELINE

CONSTRUCTION SUPPORTCOMPANIES (TOE 5-177)These units provide technical personnel andspecialized equipment. They help construc-

tion and combat engineer battalions to con-struct, rehabilitate, and maintain pipelinesystems. (They do not perform organizationalmaintenance.) These units have a l imitedindependent capability to construct, rehabil-itate, and maintain pipeline systems.

P ipel ine Cons t ruc t ion Suppor t Companiescan help using units with specialized repairs.They can provide advisory personnel to threeengineer companies of an engineer battalionengaged in pipeline construction. Unit per-sonnel can adv ise on such tasks as p ipestringing, pipe coupling, storage tank erec-tion, and pump station and dispensing facil-ity construction. Engineer Pipeline Construc-t ion Suppor t Companies a re equipped tofunction on a two-shift basis. The companieshave a limited number of bolster trailers fortransporting pipe.

ENGINEER PORT CONSTRUCTIONCOMPANIES (TOE 5-129)

In support of the petroleum distribution effort,Port Construction Companies install offshoremooring fac i l i t ies . They can instal l bothfloating and underwater pipeline. They alsoconstruct POL jetties and wharfs, and caninstall l imited POL storage facilities in the

beach area. With the support of divers, theseu n i t s c a n c o n d u c t u n d e r w a t e r p i p e l i n erepairs.


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PIPELINE DESIGN TEAMS(TOE 5-530HD)

This six-member team helps to design spe-cialized pipeline construction projects. It can

select major tank farm locations and pipelineroutes, and design related structures. Theseinclude offshore discharge and loading facil-ities and fixed dispensing equipment. Thisteam helps to manage and supervise con-struction operations. One such team is allo-cated per engineer group or brigade engagedin pipeline construction operations.

RADIOGRAPHIC WELD INSPECTION

TEAMS (TOE 5-530HJ )This three-member team performs radio-graphic inspection of pipeline welds for the

unit to which i t is attached or assigned. Oneteam should be allocated for each EngineerPort Construction Company (TOE 5-129).One team should be assigned to each Engi-neer Pipeline Construction Support Companyengaged in welded pipeline construction.

MILITARY BULK PETROLEUM DISTRIBUTION SYSTEMS

Th e Ar m y ha s u sed la r g e s ca l e p et r ol eu m t h e m id -19 80 s, w h e n a m a j or u pg r a d e of

p ip el in e di st r i bu t ion s y st e m s si n ce Wor ld m a t e r ia l s a n d e q ui pm en t t o ok pl a ce. Th eWar I I . During the wa r and short ly a f terwa rd, entire distribution system is now subdividedthe to t a l mi l i t a ry p ipe l ine sys tem became into offshore and inland systems. The basics tandardized. Standardiza t ion included the characteristics of each system and some ofb u l k f u el d i s t r i b u t i on e q u i p m e n t . Th i s t heir sa lien t fea t ur es a r e d es cr ibed in t heequipment remained largely unchanged until f o l lowing pa ragraphs .


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OFFSHORE PETROLEUMDISTRIBUTION SYSTEMS (OPDS)

The OPDS is a set of equipment and material

used to move petroleum from ships or bargesto the first storage facilities on land. TheOPDS maybe installed entirely by US Armyengineer uni ts or in conjunct ion wi th USNavy construction units. This depends uponthe specific theater or situation. The Armyengineers and Navy construction forces havethe capabili ty to extend underwater pipelineup to 4 miles from the high wa ter ma rk. Suchlines are needed where shallow waters orb l o c k e d c h a n n e l s p r e v e n t t a n k e r s f r o mentering ports . If tankers can enter and useexisting port facilities, engineers install fuel

unloading equipment at the pier or wharf .The f i rs t major s torage faci l i ty is usual lylocated within a 5-mile radius of the beach.

TACTICAL PETROLEUM

TERMINALS (TPT)The TPT has been recently developed to takea d v a n t a g e o f n e w , r a p i d l y e m p l a c e a b l e ,f lex ible s torage tanks . The s tandard TPTuses 18 of these 5,000-barrel (210,000-gallon)col laps ible tanks to provide fuel s torage .When the TPT is deployed at its maximum

size, i t requires an area of about 160 acres.

The tanks are in terconnected, f i l led , andemptied by a system of flexible hoses andtrailer-mounted pumps. The Petroleum Op-erat ing B at ta l ion is responsible for emplacingfuel tanks, hoselines, and pumps.

Substantial engineer effort may be needed tohelp the petroleum operating battal ion pre-pare th e TP T site. The area s a round the ta nksites must be cleared of vegetation, and thesites must be leveled. Earth berms must bebuilt to provide add ed support a nd horizonta lprotection for the tanks. The tank farm area

must be properly drained to prevent waterdamage and to minimize problems from fuels p i l l s o r c a t a s t r o p h i c f a i l u r e o f a t a n k .Interconnecting roads are needed within thet a n k f a r m , a s w e l l a s a c c e s s r o a d s a n dpark ing a reas f o r heavy veh ic les a t fue l

dispensing points. A water supply for firefighting may need to be developed.

BOLTED STEEL STORAGE TANKS

Bolted steel tanks with storage capacities ofup to 10,000 barrels (420,000 gallons) are stillin the supply system. These tanks are espe-cially useful at petroleum terminals in placeswh ere area restrictions preclude the optimumspacing of collapsible tanks or where morepermanent facilities are required. The erec-tion of the bolted steel tanks requires con-siderably more time and engineer effort thancollapsible tanks.

INLAND PETROLEUMDISTRIBUTION SYSTEMS (IPDS)

The IPDS is the system of pipelines, hose-lines, and storage containers that extendsfrom the shore or port as far forward towardthe comba t a rea a s p rac t i ca l . The sys temconsists of one or more main or trunk pipe-lines, pumping sta tions tha t m ove the product

through the l ine, intermediate tank farms,branch l ines to large users such as airf ields,and the head terminal at the end of the l ine.The main pipeline may bean existing civilianpipeline provided by the HN, a line captured

from the enemy, or a ta ctical m ilita ry pipelineconstructed by military engineers, or a com-bination. The construction materials used intactical mili tary pipelines are easily assem-b l e d a n d r e a d i l y a d a p t a b l e t o e x i s t i n gconditions.

MILITARY IPDS PIPEAND COUPLINGS

The new standard pipe used in the mili taryIPDS system is either a 6- or 8-inch nominaldiameter aluminum pipe. The pipe comes instandard lengths of 20 feet. The pipe ends

have special grooves rolled on the ends toallow sections of pipe to be joined with agasket and coupling. The new couplings forthe pipe are designed to be closed with a lever.The new pipe is considerably lighter than theolder steel pipe and tubing, and can be joined


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much faster and with fewer people. Alumi-num pipe comes with curved elbow sectionswhich a l low p ipe to nego t i a te tu rns and

elbows. The aluminum pipe can be cut andthe ends prepared in the f ield with specialtools held by the Engineer Pipeline Construc-tion Support Company.

PUMPS AND PUMP STATIONS

Pump stations are located along the pipelineto maintain the pressure required to moveliquid fuel . Pump stations are operated bycrews f rom the Pe t ro leum Opera t ing Ba t -talion. These crews operate pumps, maintainequipment, and may perform pipeline patrolbetween a djacent pump sta tions. The spacing

of the pump stations will depend upon thehydraulic design of the pipeline, as deter-mined by the engineer, and the anticipatedfuture requirements of the system, as deter-mined by the petroleum group. On relativelyf lat terrain, pump stations will be about 15 to

20 miles apa rt . In mountainous terrain, pumpstations may be much closer together.

Pump s ta t ions consis t o f a se t o f pumps,station fuel storage tanks, various pipelineoperating equipment, and personnel facilitiesfor the crews . The tact ica l and logis t ica lsituation will dictate the other features of thestation. The pump station should be locatedon relatively high ground to allow fuel vaporsto move away from the facil i ty . Personnelfacil i t ies should be located away from theoperating equipment because of noise andthe presence of noxious fumes.

Assembling pump s ta t ion components re-

quires th e specia lized skills of personnel fromthe Engineer Pipeline Construction SupportC o m p a n y . N e w l y i n t r o d u c e d e q u i p m e n ts i g n i f i c a n t l y r e d u c e s c o n s t r u c t i o n t i m e ,because many of the components are modu-lar ized. However , some fabr ica t ion is s t i l lrequired.

PIPELINE CONSTRUCTION AND MAINTENANCE

PLANNING PHASE

The engineer planning phase for the con-

struction of a petroleum pipeline begins assoon as the need for a pipeline has beenestablished. The ENCOM, in conjunctionwith the Petroleum Group and the Trans-porta tion G roup, determines the general r outef o r t h e p i p e l i n e . T h i s e n s u r e s t h a t t h emater i a l requ i red can be ava i l ab le whenneeded. In some cases, pipe has to be man-ufactured and shipped to the area. This mayadd months to the construction schedule.

Early determination of required constructionunits and support must be made. Transpor-

ta tion needs must be plan ned, since Engineerbattal ions have a l imited l i f t capabili ty tomove themselves. The requirement to trans-port large volumes of pipeline material couldprevent the r apid insta llation of the pipeline.

Final selection of the pipeline route beginsafter a physical reconnaissance of the areas

to be crossed. The pipeline route will havethese major characteristics:

Route follows secondary roads in order to

reduce disruption of traffic on the MSRs.

Route should be the most level ground

ava i l ab le and avo id sha rp changes inelevation. Pipeline supports and suspen-sion bridges allow the construction of theline over small and large gaps, but add tothe construction time and amount of addi-tional construction material required.

Route avoids heavily populated areas to

minimize potential problems from spillsand to reduce opportunities for tampering.


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Route can service large users such asa irfields.

Route follows natural l inear features such

as wood edges and fence rows as an aid incamouflage.

I t is essential to determine elevations alongthe route a s par t of the reconna issance. Thesedata are critical to the systems hydraulicdesign. The hydraulic design determines thelocation and number of pump stations and ofcertain control devices needed so the pipelinecan work properly.

CONSTRUCTION PHASEDifferent parts of the pipeline system can bebuilt simultaneously. As construction crewsare clearing the pipeline route, other crewscan be building gap-crossing structures orinstal l ing pump stat ions and intermediatestorage facilities. Thus, the construction of ap i p e l i n e s y s t e m r e q u i r e s a m a x i m u m o fflexibility and decentralized control of theconstruction elements. Leaders of small unitsmust be well prepared to function with aminimum of supervision, because the con-struction battalion will l ikely have elements

spread over many miles. In this way, theentire battalion can be effectively employed.

Tac t ica l s i tua t ion , ter ra in d i f f i cu l ty , andrequired supporting construction will deter-mine how t he constr uction w ill be car ried out.The joining of pipeline elements is likely to bea short end phase, with longer earlier phasesin which the ba t t a l ion works in a decen-tralized fashion.

As the pipeline is assembled, certain sectionswill have to be tested carefully to make sure

they are absolutely leak-proof. Any section ofpipe that cannot be visually inspected or isnot readi ly accessib le must meet this cr i-

terion. Sections of pipe tha t a re buried under-ground or are submerged under water must

be tested. Other critical sections include anyparts of a pipeline that are placed in tunnelsused by personnel or vehicles. Leaks in tun-nels may a l low vapors to accumula te orexpose the pipe to damage f rom movingvehicles. A fire or explosion may result.

The pipeline is best checked by pressure-testing with water. The engineer unit mustprovide water for this event. Water is intro-duced into the pipel ine and subjected toincreasing pressure for a period of time. Thepipeline must maintain the required pressure

for the specified period before the section ofpipeline can be accepted by the operatingunit. Testing with air can be used for shortersect ions of l ine, but leaks are d i f f icul t top i n p o i n t . U n d e r e x t r e m e o p e r a t i o n a l r e -quirements the testing may be authorizedusing fuel, but only as a last resort.

PIPELINE MAINTENANCE

Once the pipeline has been accepted by thepetroleum operating battalion, that unit isresponsible for maintenance. The unit willmake frequent inspections of the l ine for

visual signs of leaks and damage. The unit iscapab le o f repa i r ing minor leaks and re-placing short sections of pipeline that havebeen damaged. However, the operating unitwill need engineer support to make repairsbeyond its capability, for instance, on buriedpipe or pipe that is in an inaccessible location.

Safety is extremely important when dealingwith pipeline breaks and leaks. Spilled fuelmust be contained to reduce the f ire hazardand to prevent contamination of water sup-plies. Absolute control of all flame- or spark-

generating equipment or material within ornear the work is vital .


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