Dr.christine Groetxbach Final Presentation Bahrain May 2015

7/21/2019 Dr.christine Groetxbach Final Presentation Bahrain May 2015

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Latest Developments in

Aviation Fuel Infrastructure



Founded in Germany in 1979 Globally acknowledged for Aviation Fuel Infrastructure:

Engineering & Design, Automation & Control, Tightness

Control, Hydraulic Simulation…

Market Leader TCS© Tightness Control System Global airport reference list with more than 300 airport

projects: LHR, AMS, FRA, MUC, ATH, MAD, SVO, JFK, DFW,

A380, ANC, MEL, ADL, BNE, CAN, MLE, JNB, LED, MCT,

RUH, DMM, MED, DXB, JXB, HRI, HRG, AMM, CAI,DOH…

Designed investment volume USD 500,000,000 last 8 y

Global Service Network

Associated JIG Member

Certified DIN EN ISO 9001:2008



jet fuel clean and free of water

compliance to national and international regulations

safety and environment protection

low investment cost low operational cost

reliable fuel supply

reliable on-time servicing

trained operators

profit

Targets of Fuel Logistics



The three pillars of sustainability

Economic:

• Profit

• Cost saving

• Economic growth

• R&D

Social:

• Human and

labor rights

• Health equity

• Cultural

competence

• Life quality

Environmental:

• Environmental resource

management

• Pollution prevention

• Environmental

engineering



Virtual Simulation Model :To learn, visualize, design, verify and optimize the integrated

hydraulic system as one physical system

Design

Dimensioning the fuelling systems for the specific

requirements: high quantity of fuel in a short turnaround time

Evaluation of various design options

Identification of design defects and deficiencies

Visualization & operational validation of the system Design and verification of Automation and Control System

Integration of Hydrant and Tank Farm operation

Dynamic Simulation as

module of sustainability



Operation

Verification system dimensioning (pump capacity)

Pressure Surge Analysis / Hydraulic calculation

Reduction of energy consumption

Operator Training on all operational aspects

Dynamic Simulation as

module of sustainability



Applications Kleopatra® Simulation Study

Vessel Unloading

A380 Fuelling System

Airports worldwide



Monitoring and Control of Fuel Reception,Tanks, Hydrant Pumps etc

Monitoring and Control Hydrant Tightness

Controlling Emergency Situations EFSO

Fire Fighting Functionalities

Interface to 3rd party commercial systems

(stock accounting, into-plane operations etc.)

A SMART Brain



Reduce power consumption:Frequency control to meet the changing fuel demand by a smooth

(de)activation of equipment

Hydraulic Study to identify the optimum pressure

Protect plant equipment:

Avoid pump operation under no flow coditionsPressure Surge Analysis

Correct operating procedures:

Operator can only open a tank's outlet valve after confirmation of

correct sampling and tank release procedures

Safe operation:Identify alarm conditions and shut down of relevant installation

Control of over-filling tanks or vehicles to prevent spills

Detection of leaks:

Typically resulting from underground pipe work, pump shaft

seals...

SMART Sustainable Operation



Risk of contamination of ground water and soil due to a leak

2012 Refinery, Germany:

> 1 million litre kerosene

underground lake 42.000m2

7m below the surface

Degradation decades

Environmental protection



Environmental protection

Risk: Leaking Hydrant Systems



National Regulations: Authorities request test frequency (daily LHR AMS, FRA, MUC)

USA: frequency depending on the state (daily IAD, DCA, BWI;

up to 10y)

Increasing global awareness specifies limits

Limits usually very strict after an incidence

Standards:

JIG

EI 1540, EI 1560

Technical Rules for pipelines (Germany)

API 4716 Buried pressurized piping systems leak detection

guide

National Work Group on Leak Detection Evaluation NWGLDE

Regulation tightness integrity



JIG 2: Aviation Fuel Quality Control & OperatingStandards for Airport Depots & Hydrants (Issue 12 – 2015)

3.5.6 All new hydrant systems shall incorporate a means

of testing and proving the integrity of the system.

EI 1540

Design, Construction, Commissioning, Maintenance and

Testing of Aviation Fuelling Facilities, 5th ed Oct 2014

EI 1560Recommended practice for operation, inspection,

maintenance and commissioning of aviation fuel hydrant

systems and hydrant system extensions, 1st ed, Feb 2013



EI 15405.17 Automated Hydrant Integrity Testing System

New installations shall include automated systems.

Automated technologies:

Pressure Step,

volumetric dual pressure, pressure decay with

temperature compensation, indicator tape

Sensitivity 0,04 litres/h/m3 for section volume 200m3

Yearly performance verification



TCS® Tightness Control System

Pressure Step Method

Phase 1: High pressure test level• Valves close for section isolation

• 10 minutes equilibration

• 2 minutes measuring

Phase 2: Low pressure test level• Open a pressure relief valve

• Valves close for section isolation

• 10 minutes equilibration

• 2 minutes measuring

Phase 3: High pressure test level

• Same as Phase 1

Pressure data should be received every 2

seconds during the measurement cycles.

45 Minutes!

Physical fact: In case of a leak, the leakage volume is

bigger at high pressure than it is at a lower pressure.



Operator oriented visualization

No running TCS® test

Multiple testing against

benchmark:0.04 l/h/m3 section volume

(0.004% of line volume)

OK / FAIL /ERROR



Hydrant Integrity Testing Options

An entire hydrant system can be tested in less than one hour.

or

Single sections can be selected for testing.

Regular

monitoring

ensures safety!



Performance Verification with

Leak Simulation Equipment

FAIL!!!

Calibration with a series of

controlled leaks (orifice

with defined leak size)

According to EI1540/EI1560verification of performance

with first installation and

In regular intervals

(typically once a year)



Regular checks as an early warning

indicator for changed pipe characteristics



SMART Maintenance Management

Monitoring and control of periodical maintenance tasks anddocumentation

Compliance to JIG and recommendations of manufacturers

Documentation of extraordinary tasks

Inventory of equipment and spare part stock Tracking the history of equipment, incl time and money

spent

Easy and transparent documentation for external audits



SMART Grid Resource Management

Integration of renewable

energy sources like solar

panels and wind energy

Communication with the

surrounding facilities tooptimize the energy

consumption and production

Re-use of resources inside

the fuel farm Use of advanced and/or local

materials for buildings

Source: hansaconsult Ingenieurges mbH



Modules:

Refuelling management

system, integration in FID(S),

electronic fuel ordering, e-

ticketing

Electronic meter head/flow

computer for dispensers/

refuellers, temperature probes

Contaminant Analyzer: Qualitycheck of the last filtration by

laser sensing technology to

detect free water and dirt

Data transmission (radio,

GSM..)

Integrated Solution Into-Plane

Invoicing and Accounting

Quality by correct and near

real-time invoicing

Prove your Service Quality by

Milestone concept/fuel

messages (order, start/end of

fuelling, fuel breaks)

Prove your Product Quality by

Quality Data (water, solids)



Investigate energy consumption

Identify quick wins

Create awareness

Set target

Appoint someone to manage it

Invest in simple solutions

Make energy saving a sport

Define guidelines and manage them

SMART Teams



Any questionsPlease do not hesitate

to contact us:

Dr. Christine Groetzbach

[email protected]

Documents

Dr.christine Groetxbach Final Presentation Bahrain May 2015