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6-1. Responsibilities. This chapter explains the maintenance and repair of military pipeline systems for which engineer units may be responsible. The commanding headquarters of the constructing and operating units define what repairs are considered minor and major, based on the specific tactical situation. Quartermaster units are responsible for minor repairs and organizational and limited higher-echelon maintenance on a constructed pipeline system. Engineer units are responsible for major repairs when special engineer equipment is required and for organizational maintenance to put the system into operation. See FM 10-20 for details on the maintenance of pipeline systems.

a. Operator Maintenance. The person responsible for the day-to-day care of equipment performs operator maintenance, which is done before and during pipeline operations. Most operator maintenance is preventive maintenance. For example, the operator inspects the pumping equipment for leaks and for signs that the equipment needs adjusting or repairing. He must read the technical manuals for the equipment to be swam his repair responsibilities. The operator performs those actions that are within the limits of his capabilities and duties. He reports defects that he cannot correct to his supervisor. The operator also knows the normal operating characteristics of the equipment. For example, he should be able to tell when the equipment is making more noise than usual and when readings are not within normal operating limits.

b. Organizational Maintenance. The organization responsible for the operation and upkeep of the pipeline and related equipment and facilities performs this type of pipeline maintenance. organizational maintenance--

• Is service and repairs that authorized unit personnel are capable of performing while using the assigned tools, supplies, and test equipment.
• Includes inspecting, adjusting, lubricating, cleaning, making minor repairs, replacing parts in equipment, and servicing. The operator performs the maintenance.
• Includes unit replacement of aboveground joints of pipe, couplings, valves, and fittings; repair of small leaks using overleak clamps; and other repairs not involving construction or special handling equipment.
• Includes repair and maintenance of assemblies using authorized hand tools and small power tools. The equipment does not have to be removed from the area.

c. Support Maintenance. With this type of maintenance, the equipment is removed from the area, repaired, and then returned. Also, support maintenance requires special tools or equipment that the using organization is not authorized to use. Therefore, the using organization cannot perform this maintenance. Support maintenance includes overhauling the pump unit and repairing or reconstructing the pipeline. An example would be laying looped lines to bypass major breaks in the line.

6-2. Safety Precautions. Leaders must be aware of the hazards involved with the construction, operation, and repair of petroleum pipelines and must take measures to prevent accidents. The potential hazards must be identified and reduced before each operation is started. The following paragraphs discuss specific safety precautions pertinent to the construction and repair of pipelines and pumping stations.

a. Fire and Explosion. A constant fire and hazard explosion exists on a pipeline because of the fuels, Construction units must be aware of this during final testing of a newly constructed pipeline and during the repair of an existing pipeline. Units should use an explosimeter to determine how explosive and toxic an area is before entering it. When disconnecting a pipeline to replace damaged pipe or fittings or when a line break occurs, immediately shut down the line and close the closest block valves on each side of the break to capture as much of the fuel as possible before it becomes a fire hazard. Every opening could be a potential fire. Fire-fighting troops should accompany repair crews on major repair assignments. Observe the following precautions while repairing leaks or breaks in military pipelines:

• Keep all vehicles a safe distance from a leak.
• Approach the leak from the windward side.
• Do not approach a leak from a lower level; fuel vapors flow downhill.
• Know how to administer first aid for burns and how to give artificial respiration. Make sure you have adequate first-aid material, including burn ointment and blankets.
• Wear leakproof rubber or synthetic robber boots when standing in fuel.
• Use every precaution to prevent striking sparks when removing and replacing pipe fittings. Use sparkless brass hammers when replacing snap-joint couplings.
• Enforce and observe NO SMOKING rules.
• Never try to weld pipe holes; use clamps.
• Cover an area with petroleum fire-preventing foam even after repairing a leak or break and salvaging the fuel. The area may remain potentially dangerous for several days. Guards should be posted, and they should monitor the area for explosivity, as required.

b. Projectiles. A pipeline under pressure contains a large amount of potential energy. This energy is normally used to move fuel in the pipeline. If pipeline failure occurs, this energy is released suddenly and violently. Pipe sections and fittings can be thrown hundreds of yards. When repairing a coupled pipeline, repressurize and drain it before repairing it. Be very cautious when removing snap-joint couplings.

c. Fuel Inhalation and Skin Contact. Fuels, especially gasoline which contains lead and benzene, are potentiality dangerous to the health of personnel handling them. Inhaled vapors and prolonged skin contact may cause severe irritation. Persistent exposure to leaded gasoline can cause lead poisoning.

6-3. Coupled Pipeline.

a. Temporary Repairs. Repair small leaks in pipe sections and couplings, temporarily, by using clamps. The kind of clamp used depends on the kind of leak. It is not necessary to stop pumping operations while installing clamps. Replace the repaired pipe sections and couplings with new pipe and couplings as soon as possible.

b. Permanent Repairs. To make permanent repairs on coupled pipelines, break the line and replace the faulty coupling, pipe, or fitting. Before breaking a pipeline, drain its contents and release the pressure. Fuel vapors in the area of the break left in the line and that have collected in low areas could cause a fire, if ignited. To prevent ignition--

• Keep vehicles away from the break.
• Remove anything that could cause a spark.
• Cover any fuel that spills on the ground with fire-retarding foam.