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aviation fueling
Without fuel aircraft dont fly
Technology Update
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Aviation Fueling OperationsPlanning an aviation fueling system requires careful considerationof the many factors affecting the fueling process, as well asairport airside operations. Whether creating a fueling facility fora major international airport, a regional airport, or a militaryaviation installation, each presents a unique set of conditionsthat must be evaluated and addressed in planning, design, andimplementation of the project. Factors to be considered includethe type(s) of aircraft to be serviced (hence, the type of fuel thatwill be dispensed), the volume of air trafc, and the associated
costs. While cost may be a major decision driver, it must bebalanced with due attention to safety, environmental issues, andthe airports requirements for on-going airside functions and theefciency of the fueling process.
Types of Fuel Different categories of fuel are required depending on the typeof aircraft that may be present or planned at any given airport.These categories include commercial and military jet fuels, andaviation gasoline. Commercial jet fuel is available in three grades: Jet A standard jet fuel used in the United States Jet A-1 produced to international specications and used
at commercial airports throughout Canada and the rest ofthe world
Jet B used primarily in areas where its cold-weatherperformance characteristics are necessary
Jet fuels for military applications come in a variety of grades,primarily dependent on the type of aircraft, the militarydepartment they serve (i.e. Army, Navy, Air Force), and whetherthe aircraft are land-based or ship-based. Military jet fuels arevery similar to commercial jet fuels, the signicant differencebeing performance additives.Avgas, also known as aviation gasoline, commonly available inAvgas 100LL grade, is used by small aircraft with piston engines.The two other grades of Avgas are seldom used, and theiravailability is limited.
Fueling SystemWhether planning a new aviation fueling system or tackling amajor expansion or upgrade of an existing one, several importantfactors affecting the planning and design must be considered:
Fueling Process that covers the receipt of the fuel on site byvarious modes, storage of this fuel, and nal delivery to theaircraft
Facilities that incorporate all the infrastructure, pipelines, anddistribution systems that are required to support the fuelingoperation
Key considerations that deal with safety, environmentalprotection, re protection, airport location planning, andairport operations
Above: Tanker Truck Delivering Fuelto the AircraftRight: Aviation Fuel Arriving by RailCar at Airport Storage Depot
aviation fueling aviation fueling
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Systems and ProcessesAn airport aircraft fueling facility is comprised of three keysystems:
Receipt : the process of receiving fuel at the airport, determiningfuel quality, ltering, and metering the fuel
Storage: the system where received fuel is kept, inventoried,tested, and made available for distribution
Distribution: the system that pumps, lters, meters, anddistributes the fuel to the aircraft
Fuel receipt, storage, and much of the equipment associated withdistribution facilities are all situated in an airport fuel tank farm complex. This is typically located groundside, some distance frompassenger terminals, aircraft parking aprons, taxiways, runways,and ight lines.
Fuel Receipt Normally, receipt of fuel at airports is accomplished by eitherpipeline or transport tanker trucks. At some airports, fuel isreceived directly from railroad tank cars or marine vessels. Evenwhen fuel is received by pipeline, ofoading capability fromtransport tankers is an emergency second means of fuel receipt.Medium to large airports generally have two or more methods offuel receipt to increase reliability and avoid jeopardizing airport
operations. Regardless of the method, it is imperative that properreceiving procedures are followed to maintain fuel quality andsafety. The procedures include:
Delivery of correct fuel grade, type, and quantity, andcertication that the product meets the required specicationsPreparation of receiving storage tank(s) by proper valvepositioning and adequate tank capacityStandard tests of product samples at the beginning, mid-point,and near the end of the receiving process to ensure quality
Major equipment in fuel receiving systems usually consists ofofoading pumps, air eliminators, metering devices, pre-lters,and lters/separators.
Above Left: Jet Fuel Rail Car Being Ofoaded onConcrete Spill Containment PadLeft: Additional Storage and Supply FacilityAbove Right: Aviation Fuel Storage Tanks
Fuel StorageMost airports have fuel storage facilities congured for tanksto supply the product either directly to refueler trucks or to anunderground hydrant fueling system. For jet fuel storage, mostairports have at least two tanks, one in the receiving mode, andthe other(s) in the distribution mode. This segregation of theincoming fuel allows the operator to perform standard qualitychecks on one batch of fuel, with adequate time for any watersuspended in the product to settle to the bottom of the tank. Thisis necessary to avoid distributing fuel that does not comply withspecications, or has water contamination. Avgas storage facilitiesmay consist of only a single tank, since Avgas is not adverselyaffected by trace amounts of water in the product.
Fuel storage tanks come in many shapes and sizes,but are usually classied as aboveground, underground, or cutand cover: Aboveground tanks are made of steel, and are either vertical/
cylindrical in shape, with large capacity tanks being eld-erected, or horizontal/cylindrical, usually prefabricated andthus of lower capacity.
Underground tanks are horizontal/cylindrical in shape and canbe of single or double wall design to provide integral secondarycontainment. Usually these tanks are prefabricated with steelor berglass and have lower capacity than the abovegroundvertical storage tanks.
Cut and cover tanks are constructed of concrete and/or steel,and are of large volume and vertical design. These tanks arelocated mostly underground with a very small portion abovethe surrounding grade, and mounded over by earth. Cut andcover tanks are usually found at military air bases and whereversecurity against terrorism or sabotage is necessary.
In all cases, storage tanks must be provided with suitablesecondary containment to capture any spills, leaks, or otherunwanted product discharges. Storage tanks are equipped withancillary devices such as overll level alarms, low level alarms,automatic product level gauging, manual gauge ports, samplingports, oating suctions, access man-ways, and vents.
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Aviation Fueling ProcessIllustrating Various Systems,
Processes & Infrastructure
Fi
Fuel DistributionFuel distribution is accomplished through a system of supplypumps, lters, meters, pressure and ow control valves, and otherequipment. These systems draw fuel from the storage tanks andare usually located adjacent to the tanks in the tank farm area.From there, jet fuel is usually distributed to the aircraft by way ofa refueler truck or an underground hydrant piping system.
Fuel is distributed to vehicle loading stations where it istransferred to the refueler truck. Use of refueler trucks is acommon practice in small and medium airports and on manymilitary air bases. Although it is a much slower process than ahydrant system, as the amount delivered is limited to the truckcapacity, requiring several trips, it is usually the only means of fueldelivery at these airports. It is, nonetheless, the most economicalmeans of fuel delivery in terms of capital expenditure, and atmany airports, sufcient to meet operational needs.
A hydrant fueling system entails a network of undergroundpiping that delivers fuel from the tank farm complex to aircraftpositions at passenger terminals, hardstands, and aircraft parkingaprons. Hydrant systems are usually found at busy, mediumto large airports. They are the primary means of fuel delivery
where rapid fueling is necessary for a quick turnaround to meetairline ight schedules or military mission requirements. Theunderground piping network includes individual fueling hydrantpits situated in the apron area adjacent to the parked aircraft. Atthe hydrant pit, a hose is connected from the truck or cart to thecontrol valve located in the pit, and another hose from the samevehicle is connected directly to the aircraft. Upon activation,fuel ows through the truck or cart lters, meter, and ow andpressure controls, and then directly into the aircraft. This methodis considerably more efcient than truck fueling because the largerhydrant system pumps at the fuel farm can supply product to theaircraft continuously. In addition, hydrant systems are designedto serve numerous aircraft simultaneously. In some busy airports,the hydrant systems are quite complex and far reaching, and arecapable of serving over one hundred aircraft simultaneously.
Above: Hydrant Fueling SystemDistribution Pumps
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bution
Avgas is usually distributed by a much smaller system than whatis used for other types of fuel. One delivery method involvestaking the fuel from the storage tank(s) directly to adjacentfuel dispensers or cabinets, similar to a gas station. From thesedispensers, Avgas is supplied directly to small aircraft, whichmaneuver close to the dispenser hoses. Fuel is delivered to largeraircraft via a refueler truck.
Above: Delivering Fuel to Aircraftby Hydrant SystemLeft: Delivering Fuel to Aircraft by
Tanker Truck
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Key ConsiderationsThere are three key considerations when designing an aviationfueling system: Safety, Environmental Protection , and maintenanceof Airport Operations . Numerous systems and procedures arerequired to address these concerns.
Safety Aviation fuel is a highly ammable product requiring r igidadherence to all applicable industry and regulatory safety standards , which include:
National Fire Protection Association (NFPA) 407 Standardfor Aircraft Fuel ServicingAir Transport Association of America (ATA) SpecicationNo. 103 Standard for Jet Fuel Quality Control at AirportsAmerican Petroleum Institute (API), Petroleum EquipmentInstitute (PEI), Steel Tank Institute (STI), and Association forComposite Tanks (ACT) for storage tanks, piping, valves, lterseparators, and other equipment, inspections, testing methods,and procedures
in the hands of an alert operator.
Environmental ProtectionContainment of spills and other unintentional releases of fuel toprevent endangering the environment are of primary importanceto airport authorities. Federal, state, and local regulationsgenerally dictate the type of facilities required to comply with suchregulations. Such facilities include:
Concrete pavement and containment curbing and other spillcontrol infrastructure at truck loading and ofoading stations
Double-walled tanks, where the outer wall serves as secondarycontainment, or containment dikes around single-walled tanks Cathodic protection and special coatings applied to tanks and
pipelines to inhibit corrosion Double-walled underground piping systems with state-of-the-
art leak detection systems Independent high and high-high level alarms to avoid
overlling of storage tanks High-level shutoff systems at truck loading stations to prohibit
overlling of trucks Oil-water separators incorporated in industrial areas, such as
tank farms, to separate oil from any storm runoff
Each category and grade of fuel requires its own unique procedurefor receipt, storage, and distribution. Intermingling of fuels canresult in a highly dangerous situation for the receiving aircraft.A crucial requirement of the fueling operation, therefore,is the delivery of the correct type and grade of fuel, free ofcontaminants, in the safest manner possible. Special ltrationprocesses ensure contaminants such as water and solids (rust,scale, sand, and dirt) are kept within acceptable levels. Suchltration is usually required at three stages: when receivingfuel prior to storage, when withdrawing from storage priorto distribution, and prior to delivery to the aircraft. Standardprocedures for daily fuel quality checks are required prior todistribution.
Dangerous static electricity can result in electrical arcing whenconnections to fueling equipment are made. To avoid ignitionduring fueling, procedures and equipment must be in place toallow the equipment (vehicles, aircraft, piping, and valves) tobe brought to the same electrical potential by bonding prior tohook-up of the equipment and before commencing fueling, andremain connected until fueling is completed. One of the safetycontrols used for fuel transfer to tanker trucks or the aircraftis a deadman switch connected to a ow control valve in thetransfer equipment or on the truck itself. The ow starts when theswitch is squeezed and stops when it is released, preventing releaseof fuel into the environment, and keeping the fuel transfer process
Left: Fuel Filtering SystemBelow: Airport Airside Operations
Vapor recovery systems for Avgas facilities
Airport Operations Timely delivery of the correct, clean, and dry fuel to the aircraftis one of the most important aspects of airport operations. Tothe typical airline passenger it is an unheralded part of airportoperations, but to the many people that run a commercial airportor a military base, it is the lifeblood of that facility without fuelaircraft dont y. Accordingly, to plan and design an aviationfueling system properly, it is vital that specic, day-to-dayoperations of that airport are addressed. Often, redundancyis built into the subsystems and equipment that make up theentire aviation fueling system so that failure of one part will not
adversely impact continued airport operations. Once integratedinto the airport operations, the aviation fueling system becomesone of the most valuable assets to an airport, especially ifit is designed to accommodate future growth.
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Project Processes Facilities Key Issues HMM ServicesJohn F. KennedyInternational Airport, NYTerminal 5 RedevelopmentHydrant Fueling System
Hydrant System Filtration System Modifications Remote Truck Fill Station
Hydrant System Pipelines Pigging Facilities Hydrant, Valve, HP & LP Pits Surge Suppression Systems Emergency Shutdown Systems
Phasing of Construction Reuse of Salvaged Equipment Reconstitution of Off-Spec Fuel
Conceptual Planning, Budgeting,Preliminary/Final Design, ConstructionSupport & Commissioning
Newark Liberty InternationalAirport, NJSouth Fuel Farm Expansion
API Storage Tanks Receipt Modifications Tank Fire Protection
Tank Farm Storage Receipt & Distribution Systems Inventory Control Upgrades Fuel Farm Fire Protection
Integration of Control Systems Conceptual Planning, Preliminary/FinaDesign, Construction Support &Commissioning
Pease Air National GuardBase, NHJet Fuel Storage ComplexHydrant Fueling System
API Storage Tanks Truck Receipt/Loading Stations Hydrant Fueling System Tank Fire Protection
Tank Farm Storage Hydrant System Pipelines Hydrant, Valve, HP & LP Pits Receipt & Distribution Systems Gasoline/Diesel, Deicing Fluid & Waste
Fuel Facilities Fuels Testing Laboratory
Aircraft Apron Pavements
Phasing of Construction Pipeline Leak Detection Replacement of Apron Pavements
Conceptual Planning, Budgeting,Preliminary/Final Design, PLC SystemDesign, Environmental Permitting,Construction Support & Commissioning
Harrisburg InternationalAirport, PAFuel Farm Facility
Horizontal Storage Tanks Truck Receipt/Loading Stations
Tank Farm Storage Jet Fuel & Avgas Facilities Receipt & Distribution Systems Oil-water Separation System
Reuse of Salvaged Equipment Relocation of Storage Tanks Modification of Filtration Systems
Conceptual Planning, Budgeting,Preliminary/Final Design, ConstructionSupport & Commissioning
Westover Air ReserveBase, MAJet Fuel Storage Complex
API Storage Tanks Truck Receipt/Truck Loading Stations Fuel Transfer Systems Tank Fire Protection
Tank Farm Storage Receipt & Distribution Systems Fuel Transfer to Operating Storage
Phasing of Construction Pipeline Leak Detection Proximity to Taxiing Aircraft
Conceptual Planning, Budgeting,Preliminary/Final Design, EnvironmentalPermitting, Construction Support &Commissioning
Teterboro Airport, NJFuel Farms ConditionsAssessment
Horizontal Storage Tanks Truck Receipt/Loading Stations Secondary Containment System Tank Fire Protection Emergency Stop Systems
Tank Farm Storage Receipt & Distribution Systems Surge Suppression Systems Avgas Facilities Fuel Vehicle Parking
Reuse or Replacement of AgedEquipment
Asset Management & Fuel System Audit
Toronto PearsonInternational Airport, ONJet Fuel InfrastructureProject
Truck/Railcar/Pipeline Receipt/Storage API Storage Tanks Hydrant System Aircraft Refueler Loading Oily Wastewater Treatment Fire Protection
Hydrant System Pipelines Tank Farm Storage Receipt & Distribution Systems
Maintaining Fuel Supply to Airport Schedule Range of Aircraft Permitting & Approvals
Conceptual Planning, Budgeting,Preliminary/Final Design, ConstructionSupport & Commissioning
Halifax InternationalAirport, NSJet Fuel Storage & HandlingFacility
Truck Receipt API Storage Tanks/Containment Underground Fuel Hydrant System Aircraft Truck Refueler Loading Fire Protection
Distributions System: Storage Tanks, PumpPads & Truck Loading/Unloading Rack
Glycol Storage/Distribution Gas/Diesel Storage & Distribution Operations/Maintenance Building
Multi-Year Phased Construction Limited Space for Development Uninterrupted Fuel Supply Environmental Issues
Conceptual Planning, Budgeting,Preliminary/Final Design, PLC SystemDesign, Construction Support &Commissioning
Vancouver InternationalAirport, BCNew Jet Fuel Tank Farm
Truck Receipt API Storage Tanks Hydrant System Aircraft Truck Refueler Loading Fire Protection
Hydrant System Pipeline Tank Farm Storage Receipt & Distribution Systems
Geotechnical Structural DesignConstraints
Budget
Conceptual Planning, Budgeting &Preliminary/Final Design
Winnipeg InternationalAirport, MBFueling Facility
Truck Receipt API Storage Tanks Hydrant System Aircraft Truck Refueler Loading
Hydrant System Pipeline Tank Farm Storage Receipt & Distribution Systems Gas & Diesel Storage/Distribution Operations/Maintenance Building
Project Schedule Budget Commissioning
Preliminary/Final Design, ContractDocument Preparation & ConstructionManagement
HMM Aviation Fueling Projects & Facility Characteristics
how can hatch mott macdonald help? HMM has superior capability and experience in the planning,design, and construction of any airport fueling project.Recognizing that every fueling project is unique, we apply top-notch professional skills honed over 30 years of practice to bringinnovative, high-quality services to every aviation client. Our trulyintegrated design approach is proven to save capital, operatingand maintenance costs, and our optimal engineering solutionslead to lower life-cycle costs and sustainable results. Our goalis to give you condence that your fueling project will proceed
smoothly, and that all expectations will be met. These are th ehallmarks of our services and how Hatch Mott MacDonald canmake a difference for your next aviation fueling project.
Above: Fuel Tank Secondary Containment Structures
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Areas of Expertiseaircraft hydrant fueling systems
helicopter fueling systems
fuel tank farm complexes, fuel depots, and terminals
aboveground and underground tanksAPI inspection and repair overfill protection systems
pipelines
integrity inspectionlife remaining analysis
fuel ofoading and loading facilities:pipeline, truck, rail, and marine vessels automated truck loading systems
plc terminal automationfuel flow control systems
fuel transfer systems
fuel ltration systems
leak detection systems
fuel system re suppression/protectionvapor recovery systems
fueling process safety
cathodic protectionsystem designannual survey and condition assessment special coatings and paints for corrosion protection
airport fuel emergency shutdown systems
oily wastewater treatmentspill containment infrastructureoil-water separator systems
fuel vehicle maintenance buildings
fuel facility operational buildings and laboratories
fueling vehicle parking areas
alternative fuels receipt, storage, and distribution facilities
liquid oxygen and liquid nitrogen storage facilities
Servicesr amp services design
aircraft stand planning and design
project management
construction management
feasibility studies
master planning
planning including growth projections
programmingconceptual design
preliminary and detail design
site planning and layout
security solutions
mechanical design
electrical design
instrumentation design
piping design
cost estimating
material specicationspermitting
environmental compliance
contract administration
commissioning of systems
procurement and contracting
asset management
asset life remaining and value estimating
fuel system audits
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