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

Bulk Fuel Farm62 Tanks w/ associated pipeline

Transfer Lines6 Lines transfer all fuel from Bulk to Satellite Fuel Farms

North Transmission Lines10 Lines to Terminals 6, 7, 8

South Transmission Lines16 Lines to Terminals 1, 2, 3, 4, 5

Terminal Hydrant Lines8 Systems with unique isolation, surge

suppression, fueling schedules

Satellite Fuel Farm40 Tanks w/ associated pipeline

Project

Project conducted in phases1. Six Fuel Farm Transfer Lines2. Eight Terminal Hydrant Systems

• All individually contracted

3. 27 Transmission Lines4. 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 LinesExample: 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 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

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)

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 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

HCNA SolutionNon-utilized bypass lineJumper hoseBack-up with additional in-line valvesBuckeye repaired overdue valve bodiesAdded in separate sectionFlushed line into vactruckRestricted fuel truck accessUtilized thermal wells

ResultsArea Description

Volume (gal)

ResultTest

Method

Terminal 1 Loop A 25,000 PASS OtherTerminal 1 Loop B 25,000 PASS OtherTerminal 2 Terminal 2 407-2 11,917 PASS HCNA LDSTerminal 3 Terminal 3 405-3 11,271 PASS HCNA LDSTerminal 3 Terminal 3 405-1 33,022 PASS HCNA LDSTerminal 3 Terminal 3 405-2 13,289 PASS HCNA LDSTerminal 4 Concourse B East 9,994 PASS HCNA LDSTerminal 4 Concourse A East 23,645 PASS HCNA LDSTerminal 4 Concourse A West 13,852 PASS HCNA LDSTerminal 4 Concourse B West 16,411 PASS HCNA LDSTerminal 4 Hardstand System 1 15,331 PASS HCNA LDSTerminal 5 Terminal Five Hydrant 66,151 PASS HCNA LDSTerminal 6 System 3 6,237 PASS HCNA LDSTerminal 6 System 1 West 7,147 PASS HCNA LDSTerminal 6 System 1 East 11,589 PASS HCNA LDSTerminal 6 System 2 11,589 PASS HCNA LDSTerminal 7 System 1 22,588 PASS HCNA LDSTerminal 7 System 2 14,894 PASS HCNA LDSTerminal 7 System 3 8,461 PASS HCNA LDS

Terminal 8Main Terminal &

Concourse B21,651 PASS HCNA LDS

Terminal 8Concourse C Hydrant

Loop15,285 PASS HCNA LDS

Terminal 8 Transfer Lines 15,733 PASS HCNA LDSTransmission Line T-401-1 51,887 PASS HCNA LDSTransmission Line T-401-2 43,078 PASS HCNA LDSTransmission Line T-401-3 30,485 PASS HCNA LDSTransmission Line T-402-1 77,333 PASS HCNA LDSTransmission Line T-402-2 77,037 PASS HCNA LDSTransmission Line T-402-3 75,211 PASS HCNA LDSTransmission Line T-403-1 39,700 PASS HCNA LDSTransmission Line T-403-2 31,779 PASS HCNA LDSTransmission Line T-404-1 58,688 PASS HCNA LDSTransmission Line T-404-2 58,477 PASS HCNA LDSTransmission Line T-404-3 58,266 PASS HCNA LDS

Area DescriptionVolume

(gal)Result

Test Method

Transmission Line T-404-4 58,053 PASS HCNA LDSTransmission Line T-405-1 36,020 PASS HCNA LDSTransmission Line T-405-2 44,000 PASS HCNA LDSTransmission Line T-405-3 21,123 PASS HCNA LDSTransmission Line T-406-1 15,101 PASS HCNA LDSTransmission Line T-406-2 15,053 PASS HCNA LDSTransmission Line T-406-3 10,650 PASS HCNA LDSTransmission Line T-407-1 24,090 PASS HCNA LDSTransmission Line T-407-2 37,553 PASS HCNA LDSTransmission Line T-407-3 18,420 HCNA LDSTransmission Line T-408-1 17,600 PASS HCNA LDSTransmission Line T-408-2 20,577 PASS HCNA LDSTransmission Line Co-Gen 520 PASS HCNA LDSTransmission Line T-409-1 57,309 PASS HCNA LDSTransmission Line T-409-2 37,282 PASS HCNA LDSTransmission Line T-409-3 25,469 PASS HCNA LDS

Satellite Fuel FarmSatellite Fuel Farm

Piping117,350 PASS Tracer

Transfer Line T-201 14,981 PASS HCNA LDSTransfer Line T-202A 25,941 PASS HCNA LDSTransfer Line T-202B 25,941 PASS HCNA LDSTransfer Line T-203A 25,941 PASS HCNA LDSTransfer Line T-203B 25,941 PASS HCNA LDSTransfer Line T-204 14,981 PASS HCNA LDS

Bulk Fuel Farm F-101, F-103 8,566 PASS HCNA LDSBulk Fuel Farm F-102 4,847 PASS HCNA LDSBulk Fuel Farm F-104, F-105 4,935 PASS HCNA LDS

Bulk Fuel Farm F-26, F-23, F-24, F-25 8,466 PASS HCNA LDS

Bulk Fuel Farm F-28, F-27 4,083 PASS HCNA LDSBulk Fuel Farm F-124 2,599 PASS HCNA LDSBulk Fuel Farm F-21, F-22 520 PASS HCNA LDSBulk Fuel Farm F-120, F-123 15,828 PASS HCNA LDSBulk Fuel Farm F-122 8,154 PASS HCNA LDSBulk Fuel Farm F-121 8,101 PASS HCNA LDS

Results (continued)

Area DescriptionVolume

(gal)Result

Test Method

Bulk Fuel Farm F-115, F-117, F-119 23,939 PASS HCNA LDSBulk Fuel Farm F-118 9,582 PASS HCNA LDSBulk Fuel Farm F-116A 10,118 PASS HCNA LDSBulk Fuel Farm F-116B 2,702 PASS HCNA LDSBulk Fuel Farm F-133, F/S Header 8,108 PASS HCNA LDSBulk Fuel Farm F-132 4,388 PASS HCNA LDSBulk Fuel Farm F-134 7,393 PASS HCNA LDSBulk Fuel Farm S-102 7,849 PASS HCNA LDSBulk Fuel Farm S-101 9,700 PASS HCNA LDSBulk Fuel Farm S-103 9,162 PASS HCNA LDSBulk Fuel Farm S-104 8,734 PASS HCNA LDSBulk Fuel Farm S-105, S-204 10,917 PASS HCNA LDSBulk Fuel Farm D-21 501 PASS HCNA LDSBulk Fuel Farm D-22 504 PASS HCNA LDSBulk Fuel Farm D-23, D-24 1,700 PASS HCNA LDSBulk Fuel Farm D-26, D-25 1,117 PASS HCNA LDSBulk Fuel Farm D-27, D-28 1,723 PASS HCNA LDSBulk Fuel Farm D-29, D-30 1,607 PASS HCNA LDSBulk Fuel Farm D-31, D-32 1,490 PASS HCNA LDSBulk Fuel Farm S-106 3,363 PASS HCNA LDSBulk Fuel Farm S-108 3,383 PASS HCNA LDSBulk Fuel Farm S-107 6,795 PASS HCNA LDSBulk Fuel Farm S-109 5,497 PASS HCNA LDS

Bulk Fuel FarmD-13, D-14, D-15, D-

16671 PASS HCNA LDS

Bulk Fuel Farm S-27A, S-28A 3,348 PASS HCNA LDSBulk Fuel Farm S-28 799 PASS HCNA LDSBulk Fuel Farm S-27 1,470 PASS HCNA LDSBulk Fuel Farm S-31 2,003 PASS HCNA LDSBulk Fuel Farm S-114 352 PASS HCNA LDSBulk Fuel Farm D-17, D-19 538 PASS HCNA LDSBulk Fuel Farm S-30 1,065 PASS HCNA LDSBulk Fuel Farm S-29 194 PASS HCNA LDSBulk Fuel Farm S-21, S-22 1,289 PASS HCNA LDS

Area DescriptionVolume

(gal)Result

Test Method

Bulk Fuel Farm D-20 395 PASS HCNA LDSBulk Fuel Farm D-33 1,097 PASS HCNA LDSBulk Fuel Farm D-34 1,059 PASS HCNA LDSBulk Fuel Farm D-35, D-36 2,023 PASS HCNA LDSBulk Fuel Farm D-37, D-38 1,882 PASS HCNA LDS

Bulk Fuel FarmD-39, D-40, D-41, D-

42928 PASS HCNA LDS

Bulk Fuel Farm S-203 1,634 PASS HCNA LDSBulk Fuel Farm S-201 1,065 PASS HCNA LDSBulk Fuel Farm S-202 1,827 PASS HCNA LDSBulk Fuel Farm T-208 470 PASS HCNA LDSBulk Fuel Farm S-117 8,443 PASS HCNA LDSBulk Fuel Farm P-35 260 PASS HCNA LDSBulk Fuel Farm S-115 & T-211 10,138 PASS HCNA LDSBulk Fuel Farm S-116 9,994 PASS HCNA LDSBulk Fuel Farm S-118 7,557 PASS HCNA LDSBulk Fuel Farm S-119 4,243 PASS HCNA LDSBulk Fuel Farm S-120, S-121 9,872 PASS HCNA LDSBulk Fuel Farm S-122, S-123 13,350 PASS HCNA LDSBulk Fuel Farm D-43, D-44 1,779 PASS HCNA LDSBulk Fuel Farm D-45, D-46 1,630 PASS HCNA LDSBulk Fuel Farm D-47, D-48 1,674 PASS HCNA LDSBulk Fuel Farm D-49, D-50 1,718 PASS HCNA LDSBulk Fuel Farm S-103 11,346 PASS HCNA LDSBulk Fuel Farm S-102 11,416 PASS HCNA LDSBulk Fuel Farm S-101 11,502 PASS HCNA LDSBulk Fuel Farm F/S Header 1,292 PASS HCNA LDSBulk Fuel Farm F-120 3,337 PASS HCNA LDSBulk Fuel Farm F-119 3,877 PASS HCNA LDSBulk Fuel Farm F-127 3,478 PASS HCNA LDSBulk Fuel Farm Fill F/S 7&8 20,348 PASS HCNA 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, LLC200 International DriveBldg. 120Portsmouth, NH 03801T: 603.422.8833M: 603.828.1670F: 603.422.8865cfenton@hcna-llc.comwww.hcna-llc.com

Fill F/S 7,8

Fuel Farm Overviews