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

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 Satellite Fuel Farm

6 Lines transfer all fuel from 40 Tanks w/ associated pipeline
Bulk to Satellite Fuel Farms

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 Satellite Fuel Farm

127 pipeline test sections  72 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)
 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
 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 Solution
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
 Results
Volume Test Volume Test
Area Description Result Area Description Result
(gal) Method (gal) Method
Terminal 1 Loop A 25,000 PASS Other Transmission Line T-404-4 58,053 PASS HCNA LDS
Terminal 1 Loop B 25,000 PASS Other Transmission Line T-405-1 36,020 PASS HCNA LDS
Terminal 2 Terminal 2 407-2 11,917 PASS HCNA LDS Transmission Line T-405-2 44,000 PASS HCNA LDS
Terminal 3 Terminal 3 405-3 11,271 PASS HCNA LDS Transmission Line T-405-3 21,123 PASS HCNA LDS
Terminal 3 Terminal 3 405-1 33,022 PASS HCNA LDS Transmission Line T-406-1 15,101 PASS HCNA LDS
Terminal 3 Terminal 3 405-2 13,289 PASS HCNA LDS Transmission Line T-406-2 15,053 PASS HCNA LDS
Terminal 4 Concourse B East 9,994 PASS HCNA LDS Transmission Line T-406-3 10,650 PASS HCNA LDS
Terminal 4 Concourse A East 23,645 PASS HCNA LDS Transmission Line T-407-1 24,090 PASS HCNA LDS
Terminal 4 Concourse A West 13,852 PASS HCNA LDS Transmission Line T-407-2 37,553 PASS HCNA LDS
Terminal 4 Concourse B West 16,411 PASS HCNA LDS Transmission Line T-407-3 18,420 HCNA LDS
Terminal 4 Hardstand System 1 15,331 PASS HCNA LDS Transmission Line T-408-1 17,600 PASS HCNA LDS
Terminal 5 Terminal Five Hydrant 66,151 PASS HCNA LDS Transmission Line T-408-2 20,577 PASS HCNA LDS
Terminal 6 System 3 6,237 PASS HCNA LDS Transmission Line Co-Gen 520 PASS HCNA LDS
Terminal 6 System 1 West 7,147 PASS HCNA LDS Transmission Line T-409-1 57,309 PASS HCNA LDS
Terminal 6 System 1 East 11,589 PASS HCNA LDS Transmission Line T-409-2 37,282 PASS HCNA LDS
Terminal 6 System 2 11,589 PASS HCNA LDS Transmission Line T-409-3 25,469 PASS HCNA LDS
Terminal 7 System 1 22,588 PASS HCNA LDS Satellite Fuel Farm
Satellite Fuel Farm 117,350 PASS Tracer
Terminal 7 System 2 14,894 PASS HCNA LDS Piping
Terminal 7 System 3 8,461 PASS HCNA LDS Transfer Line T-201 14,981 PASS HCNA LDS
Main Terminal & Transfer Line T-202A 25,941 PASS HCNA LDS
Terminal 8 21,651 PASS HCNA LDS Transfer Line T-202B 25,941 PASS HCNA LDS
Concourse B
Concourse C Hydrant Transfer Line T-203A 25,941 PASS HCNA LDS
Terminal 8 15,285 PASS HCNA LDS Transfer Line T-203B 25,941 PASS HCNA LDS
Loop
Terminal 8 Transfer Lines 15,733 PASS HCNA LDS Transfer Line T-204 14,981 PASS HCNA LDS
Transmission Line T-401-1 51,887 PASS HCNA LDS Bulk Fuel Farm F-101, F-103 8,566 PASS HCNA LDS
Transmission Line T-401-2 43,078 PASS HCNA LDS Bulk Fuel Farm F-102 4,847 PASS HCNA LDS
Transmission Line T-401-3 30,485 PASS HCNA LDS Bulk Fuel Farm F-104, F-105 4,935 PASS HCNA LDS
Transmission Line T-402-1 77,333 PASS HCNA LDS Bulk Fuel Farm F-26, F-23, F-24, F-25 8,466 PASS HCNA LDS
Transmission Line T-402-2 77,037 PASS HCNA LDS
Transmission Line T-402-3 75,211 PASS HCNA LDS Bulk Fuel Farm F-28, F-27 4,083 PASS HCNA LDS
Transmission Line T-403-1 39,700 PASS HCNA LDS Bulk Fuel Farm F-124 2,599 PASS HCNA LDS
Transmission Line T-403-2 31,779 PASS HCNA LDS Bulk Fuel Farm F-21, F-22 520 PASS HCNA LDS
Transmission Line T-404-1 58,688 PASS HCNA LDS Bulk Fuel Farm F-120, F-123 15,828 PASS HCNA LDS
Transmission Line T-404-2 58,477 PASS HCNA LDS Bulk Fuel Farm F-122 8,154 PASS HCNA LDS
Transmission Line T-404-3 58,266 PASS HCNA LDS Bulk Fuel Farm F-121 8,101 PASS HCNA LDS
Results (continued)
Volume Test Volume Test
Area Description Result Area Description Result
(gal) Method (gal) Method
Bulk Fuel Farm F-115, F-117, F-119 23,939 PASS HCNA LDS Bulk Fuel Farm D-20 395 PASS HCNA LDS
Bulk Fuel Farm F-118 9,582 PASS HCNA LDS Bulk Fuel Farm D-33 1,097 PASS HCNA LDS
Bulk Fuel Farm F-116A 10,118 PASS HCNA LDS Bulk Fuel Farm D-34 1,059 PASS HCNA LDS
Bulk Fuel Farm F-116B 2,702 PASS HCNA LDS Bulk Fuel Farm D-35, D-36 2,023 PASS HCNA LDS
Bulk Fuel Farm F-133, F/S Header 8,108 PASS HCNA LDS Bulk Fuel Farm D-37, D-38 1,882 PASS HCNA LDS
Bulk Fuel Farm F-132 4,388 PASS HCNA LDS D-39, D-40, D-41, D-
Bulk Fuel Farm 928 PASS HCNA LDS
Bulk Fuel Farm F-134 7,393 PASS HCNA LDS 42
Bulk Fuel Farm S-102 7,849 PASS HCNA LDS Bulk Fuel Farm S-203 1,634 PASS HCNA LDS
Bulk Fuel Farm S-101 9,700 PASS HCNA LDS Bulk Fuel Farm S-201 1,065 PASS HCNA LDS
Bulk Fuel Farm S-103 9,162 PASS HCNA LDS Bulk Fuel Farm S-202 1,827 PASS HCNA LDS
Bulk Fuel Farm S-104 8,734 PASS HCNA LDS Bulk Fuel Farm T-208 470 PASS HCNA LDS
Bulk Fuel Farm S-105, S-204 10,917 PASS HCNA LDS Bulk Fuel Farm S-117 8,443 PASS HCNA LDS
Bulk Fuel Farm D-21 501 PASS HCNA LDS Bulk Fuel Farm P-35 260 PASS HCNA LDS
Bulk Fuel Farm D-22 504 PASS HCNA LDS Bulk Fuel Farm S-115 & T-211 10,138 PASS HCNA LDS
Bulk Fuel Farm D-23, D-24 1,700 PASS HCNA LDS Bulk Fuel Farm S-116 9,994 PASS HCNA LDS
Bulk Fuel Farm D-26, D-25 1,117 PASS HCNA LDS Bulk Fuel Farm S-118 7,557 PASS HCNA LDS
Bulk Fuel Farm D-27, D-28 1,723 PASS HCNA LDS Bulk Fuel Farm S-119 4,243 PASS HCNA LDS
Bulk Fuel Farm D-29, D-30 1,607 PASS HCNA LDS Bulk Fuel Farm S-120, S-121 9,872 PASS HCNA LDS
Bulk Fuel Farm D-31, D-32 1,490 PASS HCNA LDS Bulk Fuel Farm S-122, S-123 13,350 PASS HCNA LDS
Bulk Fuel Farm S-106 3,363 PASS HCNA LDS Bulk Fuel Farm D-43, D-44 1,779 PASS HCNA LDS
Bulk Fuel Farm S-108 3,383 PASS HCNA LDS Bulk Fuel Farm D-45, D-46 1,630 PASS HCNA LDS
Bulk Fuel Farm S-107 6,795 PASS HCNA LDS Bulk Fuel Farm D-47, D-48 1,674 PASS HCNA LDS
Bulk Fuel Farm S-109 5,497 PASS HCNA LDS Bulk Fuel Farm D-49, D-50 1,718 PASS HCNA LDS
D-13, D-14, D-15, D- Bulk Fuel Farm S-103 11,346 PASS HCNA LDS
Bulk Fuel Farm 671 PASS HCNA LDS
16 Bulk Fuel Farm S-102 11,416 PASS HCNA LDS
Bulk Fuel Farm S-27A, S-28A 3,348 PASS HCNA LDS Bulk Fuel Farm S-101 11,502 PASS HCNA LDS
Bulk Fuel Farm S-28 799 PASS HCNA LDS Bulk Fuel Farm F/S Header 1,292 PASS HCNA LDS
Bulk Fuel Farm S-27 1,470 PASS HCNA LDS Bulk Fuel Farm F-120 3,337 PASS HCNA LDS
Bulk Fuel Farm S-31 2,003 PASS HCNA LDS Bulk Fuel Farm F-119 3,877 PASS HCNA LDS
Bulk Fuel Farm S-114 352 PASS HCNA LDS Bulk Fuel Farm F-127 3,478 PASS HCNA LDS
Bulk Fuel Farm D-17, D-19 538 PASS HCNA LDS Bulk Fuel Farm Fill F/S 7&8 20,348 PASS HCNA LDS
Bulk Fuel Farm S-30 1,065 PASS HCNA LDS
Bulk Fuel Farm S-29 194 PASS HCNA LDS
Bulk Fuel Farm S-21, S-22 1,289 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, LLC
200 International Drive
Bldg. 120
Portsmouth, NH 03801
T: 603.422.8833
M: 603.828.1670
F: 603.422.8865
cfenton@hcna-llc.com
www.hcna-llc.com
Fill F/S 7,8
Fuel Farm Overviews