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Aviation Fuel System Leak Detection at JFK Intl Airport, NY

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Presentation on theme: "Aviation Fuel System Leak Detection at JFK Intl Airport, NY"— Presentation transcript:

1 Aviation Fuel System Leak Detection at JFK Intl Airport, NY
Charlie Fenton - HCNA

2 Why Test? New York State DEC 10 year MOSF pipeline testing requirement
Section 6NYCRR, Part “Handling and Storage of Petroleum” Standard Test Procedures for Evaluating Leak Detection Methods: Pipeline Leak Detection Systems, EPSA/530/UST-90/010 Leak Detection System Technology Requirements 3rd Party Evaluated Listing on NWGLDE MDLR of .0038% line normal operating pressure with a PD of 95% and PFA of 5%

3 JFK Airport Fuel System-Overview
North Transmission Lines 10 Lines to Terminals 6, 7, 8 Bulk Fuel Farm 62 Tanks w/ associated pipeline Terminal Hydrant Lines 8 Systems with unique isolation, surge suppression, fueling schedules Transfer Lines 6 Lines transfer all fuel from Bulk to Satellite Fuel Farms Satellite Fuel Farm 40 Tanks w/ associated pipeline South Transmission Lines 16 Lines to Terminals 1, 2, 3, 4, 5

4 Project Project conducted in phases Common to all projects
Six Fuel Farm Transfer Lines Eight Terminal Hydrant Systems All individually contracted 27 Transmission Lines Bulk and Satellite Fuel Farm Tank Lines Common to all projects Testing scheduled with fuel operator Operations would need to continue Isolation required for every line tested

5 HCNA Leak Detection System-Concept
Dual Pressure Step Method Test section must be fully isolated for duration of test No fuel movement during test Connect Trailer to Test Section 45 minute test duration Capable of detecting a leak of gal/hr or 0.002% of line volume at a PD>95% and PFA<5% at reference pressure of 145psi Leak Simulation confirms Test Result

6 Project Phase 1: Bulk to Satellite Transfer Lines - “Lifeline of JFK”
Proving the concept: Will testing at JFK work??? September 28-29, 2009: All parties involved Testing Successful! Concept Proven!!

7 Project Phase 2: Terminal Hydrant Pipeline
Contracted individually for each terminal Unique testing conditions, scheduling, and configurations for each terminal To accommodate fueling operations, testing was performed during the day and night Strict 4 hour hydrant shutdown windows Escort required at all times

8 JFK Hydrant Line Testing Example: Terminal 4
9 hydrant lines 5 separate test sections 2 concourses + hardstand Isolation of fuel lines Four isolation pits 16 surge suppressor pits Test connections HPVs and/or LPDs Jumper hoses Day/night scheduling Vault access

9 Project Phase 3: Transmission Lines
26 lines transmit fuel from Satellite Fuel Farm to each terminal’s hydrant lines 3 or 4 transmission lines dedicated to each of the 8 terminals HCNA test connections made at Satellite Fuel Farm Coordinated with each terminal which lines would be shutdown for testing PA assisted HCNA in isolation procedures Performed at each isolation vault adjacent to terminals When possible, multiple sections tested simultaneously

10 JFK Transmission Lines Example: Terminal 1
At least one line allocated for fueling operations during testing Isolation vault accessed in busy fueling apron PA assistance No contractor needed for isolation requirements

11 Project Phase 4: Fuel Farms
Bulk Fuel Farm Satellite Fuel Farm 127 pipeline test sections Consolidated into 73 after testing was complete Using HCNA LDS, operations continued despite testing timing and fuel rerouting Testing completed in 12 weeks (51 days of testing) 72 pipeline test sections No impact to fueling operations Using chemical marker technology, operations continued despite testing Testing completed in 7 weeks

12 Bulk Fuel Farm Test Section “Fill F/S 7,8”
Constant operational use Immediately downstream of Buckeye Partners, L.P. operations Inactive headers Excessive air Above and below ground pipe segments Trapped air Valves Check valves Poor isolating butterfly valves (BFV) at filter station Poor isolating double block and bleed valves on Buckeye manifold Non-functioning plug valves No test connection points

13 Bulk Fuel Farm Test Section “Fill F/S 7,8”
Problem HCNA Solution Constant operational use Check valves Poor isolation of butterfly valves Poor isolation on Buckeye manifold Non-functioning plug valves Trapped air in high point areas High traffic area by testing rig Lack of connection points Non-utilized bypass line Jumper hose Back-up with additional in-line valves Buckeye repaired overdue valve bodies Added in separate section Flushed line into vactruck Restricted fuel truck access Utilized thermal wells

14 Results

15 Results (continued)

16 Conclusion Tightness Testing the most complex, largest Airport fuel system in U.S. 20,500,000 gallons of total fuel storage at any time 2,078,000 gallons of line fill ~3,500,000 gallons of daily throughput Replenishing pipeline about 2x per day Successfully performed all leak detection activities without any impact on Airport Operations Right plan, right partners Successfully tested and complied with State Requirements We did it So can you!

17 Questions? Charlie Fenton Hansa Consult of North America, LLC
200 International Drive Bldg. 120 Portsmouth, NH 03801 T: M: F:

18 Fill F/S 7,8

19 Fuel Farm Overviews

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