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Latest Developments in

Aviation Fuel Infrastructure

Associated JIG Member


Certified DIN EN ISO 9001:2008

Founded in Germany in 1979


Globally acknowledged for Aviation Fuel Infrastructure:
Engineering & Design, Automation & Control, Tightness
Control, Hydraulic Simulation
Market Leader TCS Tightness Control System
Global airport reference list with more than 300 airport
projects: LHR, AMS, FRA, MUC, ATH, MAD, SVO, JFK, DFW,
A380, ANC, MEL, ADL, BNE, CAN, MLE, JNB, LED, MCT,
RUH, DMM, MED, DXB, JXB, HRI, HRG, AMM, CAI, DOH
Designed investment volume USD 500,000,000 last 8 y
Global Service Network

Targets of Fuel Logistics

jet fuel clean and free of water


compliance to national and international regulations
safety and environment protection
low investment cost
low operational cost
reliable fuel supply
reliable on-time servicing
trained operators
profit

The three pillars of sustainability


Social:
Human and
labor rights
Health equity
Cultural
competence
Life quality

Environmental:
Environmental resource
management
Pollution prevention
Environmental
engineering

Economic:
Profit
Cost saving
Economic growth
R&D

Dynamic Simulation as
module of sustainability
Virtual Simulation Model :
To learn, visualize, design, verify and optimize the integrated
hydraulic system as one physical system

Design
Dimensioning the fuelling systems for the specific
requirements: high quantity of fuel in a short turnaround time
Evaluation of various design options
Identification of design defects and deficiencies
Visualization & operational validation of the system
Design and verification of Automation and Control System
Integration of Hydrant and Tank Farm operation

Dynamic Simulation as
module of sustainability
Operation
Verification system dimensioning (pump capacity)
Pressure Surge Analysis / Hydraulic calculation
Reduction of energy consumption
Operator Training on all operational aspects

Applications Kleopatra Simulation Study

A380 Fuelling System

Airports worldwide
Vessel Unloading

A SMART Brain
Monitoring and Control of Fuel Reception,
Tanks, Hydrant Pumps etc

Monitoring and Control Hydrant Tightness


Controlling Emergency Situations EFSO
Fire Fighting Functionalities

Interface to 3rd party commercial systems


(stock accounting, into-plane operations etc.)

SMART Sustainable Operation


Reduce power consumption:
Frequency control to meet the changing fuel demand by a smooth
(de)activation of equipment
Hydraulic Study to identify the optimum pressure
Protect plant equipment:
Avoid pump operation under no flow coditions
Pressure Surge Analysis
Correct operating procedures:
Operator can only open a tank's outlet valve after confirmation of
correct sampling and tank release procedures
Safe operation:
Identify alarm conditions and shut down of relevant installation
Control of over-filling tanks or vehicles to prevent spills
Detection of leaks:
Typically resulting from underground pipe work, pump shaft
seals...

Environmental protection

Risk of contamination of ground water and soil due to a leak


2012 Refinery, Germany:
> 1 million litre kerosene
underground lake 42.000m2
7m below the surface
Degradation decades

Environmental protection

Risk: Leaking Hydrant Systems

Regulation tightness integrity


National Regulations:
Authorities request test frequency (daily LHR AMS, FRA, MUC)
USA: frequency depending on the state (daily IAD, DCA, BWI;
up to 10y)
Increasing global awareness specifies limits
Limits usually very strict after an incidence
Standards:
JIG
EI 1540, EI 1560
Technical Rules for pipelines (Germany)
API 4716 Buried pressurized piping systems leak detection
guide
National Work Group on Leak Detection Evaluation NWGLDE

JIG 2: Aviation Fuel Quality Control & Operating


Standards for Airport Depots & Hydrants (Issue 12 2015)
3.5.6 All new hydrant systems shall incorporate a means
of testing and proving the integrity of the system.
EI 1540
Design, Construction, Commissioning, Maintenance and
Testing of Aviation Fuelling Facilities, 5th ed Oct 2014
EI 1560
Recommended practice for operation, inspection,
maintenance and commissioning of aviation fuel hydrant
systems and hydrant system extensions, 1st ed, Feb 2013

EI 1540
5.17 Automated Hydrant Integrity Testing System

New installations shall include automated systems.


Automated technologies:
Pressure Step,
volumetric dual pressure, pressure decay with
temperature compensation, indicator tape
Sensitivity 0,04 litres/h/m3 for section volume 200m3
Yearly performance verification

TCS Tightness Control System


Pressure Step Method
Phase 1: High pressure test level
Valves close for section isolation
10 minutes equilibration
2 minutes measuring
Phase 2: Low pressure test level
Open a pressure relief valve
Valves close for section isolation
Pressure data should be received every 2
10 minutes equilibration
seconds during the measurement cycles.
2 minutes measuring

45 Minutes!
Phase 3: High pressure test level
Same as Phase 1

Physical fact: In case of a leak, the leakage volume is


bigger at high pressure than it is at a lower pressure.

Operator oriented visualization

No running TCS test

Multiple testing against


benchmark:
0.04 l/h/m3 section volume
(0.004% of line volume)
OK / FAIL /ERROR

Hydrant Integrity Testing Options

An entire hydrant system can be tested in less than one hour.


or
Single sections can be selected for testing.

Regular
monitoring
ensures safety!

Performance Verification with


Leak Simulation Equipment
Calibration with a series of
controlled leaks (orifice
with defined leak size)
According to EI1540/EI1560
verification of performance
with first installation and
In regular intervals
(typically once a year)

FAIL!!!

Regular checks as an early warning


indicator for changed pipe characteristics

SMART Maintenance Management

Monitoring and control of periodical maintenance tasks and


documentation
Compliance to JIG and recommendations of manufacturers
Documentation of extraordinary tasks
Inventory of equipment and spare part stock
Tracking the history of equipment, incl time and money
spent
Easy and transparent documentation for external audits

SMART Grid Resource Management

Integration of renewable
energy sources like solar
panels and wind energy
Communication with the
surrounding facilities to
optimize the energy
consumption and production
Re-use of resources inside
the fuel farm
Use of advanced and/or local
materials for buildings

Source: hansaconsult Ingenieurges mbH

Integrated Solution Into-Plane


Modules:
Refuelling
management Invoicing and Accounting
Quality by correct and near
system, integration in FID(S),
real-time invoicing
electronic fuel ordering, eticketing
Electronic meter head/flow Prove your Service Quality by
Milestone concept/fuel
computer
for
dispensers/
messages (order, start/end of
refuellers, temperature probes
fuelling, fuel breaks)
Contaminant Analyzer: Quality Prove your Product Quality by
Quality Data (water, solids)
check of the last filtration by
laser sensing technology to
detect free water and dirt
Data
transmission
(radio,
GSM..)

SMART Teams

Investigate energy consumption


Identify quick wins
Create awareness
Set target
Appoint someone to manage it
Invest in simple solutions
Make energy saving a sport
Define guidelines and manage them

Any questions
Please do not hesitate
to contact us:

Dr. Christine Groetzbach


cgroetzbach@hansaconsult.com