John F. Kennedy Intl Airport Case Study

Report
Aviation Fuel System
Leak Detection
at JFK Intl Airport, NY
Charlie Fenton - HCNA
Why Test?
New York State DEC 10 year MOSF pipeline
testing requirement
 Section 6NYCRR, Part 613.6 “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 volume @ normal operating
pressure with a PD of 95% and PFA of 5%
JFK Airport Fuel System-Overview
North Transmission Lines
Bulk Fuel Farm
10 Lines to Terminals 6, 7, 8
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
Project
Project conducted in phases
1. Six Fuel Farm Transfer Lines
2. Eight Terminal Hydrant Systems
• All individually contracted
3. 27 Transmission Lines
4. 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
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 0.068 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
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!!
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
JFK Hydrant Line
Testing Example: Terminal 4
 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
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
JFK Transmission Lines
Example: Terminal 1
 3 Transmission Lines
 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
Project Phase 4:
Fuel Farms
Bulk 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)
Satellite Fuel Farm
 72 pipeline test sections
 No impact to fueling
operations
 Using chemical marker
technology, operations
continued despite testing
 Testing completed in 7
weeks
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
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 inline valves
Buckeye repaired overdue
valve bodies
Added in separate section
Flushed line into vactruck
Restricted fuel truck access
Utilized thermal wells
Results
Area
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Description
1
1
2
3
3
3
4
4
4
4
4
5
6
6
6
6
7
7
7
Terminal 8
Terminal 8
Terminal 8
Transmission Line
Transmission Line
Transmission Line
Transmission Line
Transmission Line
Transmission Line
Transmission Line
Transmission Line
Transmission Line
Transmission Line
Transmission Line
Loop A
Loop B
Terminal 2 407-2
Terminal 3 405-3
Terminal 3 405-1
Terminal 3 405-2
Concourse B East
Concourse A East
Concourse A West
Concourse B West
Hardstand System 1
Terminal Five Hydrant
System 3
System 1 West
System 1 East
System 2
System 1
System 2
System 3
Main Terminal &
Concourse B
Concourse C Hydrant
Loop
Transfer Lines
T-401-1
T-401-2
T-401-3
T-402-1
T-402-2
T-402-3
T-403-1
T-403-2
T-404-1
T-404-2
T-404-3
Volume
(gal)
Result
Test
Method
25,000
25,000
11,917
11,271
33,022
13,289
9,994
23,645
13,852
16,411
15,331
66,151
6,237
7,147
11,589
11,589
22,588
14,894
8,461
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
Other
Other
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
HCNA LDS
21,651
PASS
HCNA LDS
15,285
PASS
HCNA LDS
15,733
51,887
43,078
30,485
77,333
77,037
75,211
39,700
31,779
58,688
58,477
58,266
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
Area
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Description
Line
Line
Line
Line
Line
Line
Line
Line
Line
Line
Line
Line
Line
Line
Line
Line
Volume
(gal)
Result
Test
Method
Transfer Line
Transfer Line
Transfer Line
Transfer Line
Transfer Line
Transfer Line
Bulk Fuel Farm
Bulk Fuel Farm
Bulk Fuel Farm
T-404-4
T-405-1
T-405-2
T-405-3
T-406-1
T-406-2
T-406-3
T-407-1
T-407-2
T-407-3
T-408-1
T-408-2
Co-Gen
T-409-1
T-409-2
T-409-3
Satellite Fuel Farm
Piping
T-201
T-202A
T-202B
T-203A
T-203B
T-204
F-101, F-103
F-102
F-104, F-105
Bulk Fuel Farm
F-26, F-23, F-24, F-25
8,466
PASS
HCNA LDS
F-28, F-27
F-124
F-21, F-22
F-120, F-123
F-122
F-121
4,083
2,599
520
15,828
8,154
8,101
PASS
PASS
PASS
PASS
PASS
PASS
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
Satellite Fuel Farm
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Farm
Farm
Farm
Farm
Farm
Farm
58,053
36,020
44,000
21,123
15,101
15,053
10,650
24,090
37,553
18,420
17,600
20,577
520
57,309
37,282
25,469
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
117,350
PASS
14,981
25,941
25,941
25,941
25,941
14,981
8,566
4,847
4,935
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
PASS
PASS
PASS
PASS
PASS
PASS
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
Tracer
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
Results (continued)
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Area
Description
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
F-115, F-117, F-119
F-118
F-116A
F-116B
F-133, F/S Header
F-132
F-134
S-102
S-101
S-103
S-104
S-105, S-204
D-21
D-22
D-23, D-24
D-26, D-25
D-27, D-28
D-29, D-30
D-31, D-32
S-106
S-108
S-107
S-109
D-13, D-14, D-15, D16
S-27A, S-28A
S-28
S-27
S-31
S-114
D-17, D-19
S-30
S-29
S-21, S-22
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Bulk Fuel Farm
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Volume
(gal)
Result
Test
Method
23,939
9,582
10,118
2,702
8,108
4,388
7,393
7,849
9,700
9,162
8,734
10,917
501
504
1,700
1,117
1,723
1,607
1,490
3,363
3,383
6,795
5,497
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
671
PASS
HCNA LDS
3,348
799
1,470
2,003
352
538
1,065
194
1,289
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
Bulk
Bulk
Bulk
Bulk
Bulk
Area
Description
Fuel
Fuel
Fuel
Fuel
Fuel
D-20
D-33
D-34
D-35, D-36
D-37, D-38
D-39, D-40, D-41, D42
S-203
S-201
S-202
T-208
S-117
P-35
S-115 & T-211
S-116
S-118
S-119
S-120, S-121
S-122, S-123
D-43, D-44
D-45, D-46
D-47, D-48
D-49, D-50
S-103
S-102
S-101
F/S Header
F-120
F-119
F-127
Fill F/S 7&8
Farm
Farm
Farm
Farm
Farm
Bulk Fuel Farm
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Farm
Volume
(gal)
Result
Test
Method
395
1,097
1,059
2,023
1,882
PASS
PASS
PASS
PASS
PASS
HCNA
HCNA
HCNA
HCNA
HCNA
928
PASS
HCNA LDS
1,634
1,065
1,827
470
8,443
260
10,138
9,994
7,557
4,243
9,872
13,350
1,779
1,630
1,674
1,718
11,346
11,416
11,502
1,292
3,337
3,877
3,478
20,348
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
PASS
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
HCNA
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
LDS
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!
Questions?
Charlie Fenton
Hansa Consult of North
America, LLC
200 International Drive
Bldg. 120
Portsmouth, NH 03801
T: 603.422.8833
M: 603.828.1670
F: 603.422.8865
[email protected]
www.hcna-llc.com
Fill F/S 7,8
Fuel Farm Overviews

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