HC-Brochure-28-08-19

Company Brochure

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The information contained in these documents is privileged and only for the information of the
intended recipient and may not be used, published or redistributed without the prior written consent of
hansaconsult Ingenieurgesellschaft mbH.

June 2019

The Company Profile

hansaconsult has been founded in 1979 to provide airports, tank
farm operators and oil companies with safe and economic fuel
infrastructure. Today hansaconsult is an associated member
of JIG Joint Inspection Group, certified against ISO 9001:2008
and globally acknowledged as competence center for fuel
infrastructure.

hansaconsult offers global expertise of experienced engineers,
technicians and drafts-men covering all disciplines of
mechanical and process engineering, pipeline construction,
electrical engineering, automation, information technology, civil
engineering and construction. Our staff is equipped with the
most advanced technology and CAD systems.

Our compliance to international regulation, standards and
guidelines goes hand in hand with successful projects.
Competent contacts in our global offices take care of all local
needs and make you feel comfortable.



© 2019 hansaconsult. All Rights Reserved

40 YEARS OF RELIABLE ENGINEERING
IN THE AVIATION FUEL INFRASTRUCTURE

© 2019 hansaconsult. All Rights Reserved

What we do? Basic Engineering

Our focus at hansaconsult providing worldwide, economical safety • Basic Design (Process, Electrical, Automation)
solutions for the aviation fuel business. The service spectrum covers • Basic Layout and Specifications
the tank farm life cycle: design and engineering of tank farms, • Typical Drawings
tightness control by the system TCS (third party certified e.g. TÜV, • Hydraulic Calculation
Ken Wilcox Association) and automation solutions. Our clients benefit • Time Scheduling
in all project stages from competent consulting of our experienced • Cost Evaluation
team.
• Official Approval Planning
Design Over the facility‘s life cycle
Detail Engineering
Masterplan / Feasibility Study
• Value Engineering
• Economic and operational analysis infrastructure • Detail Design (Process, Electrical, Automation)
• Storage capacity calculations • Detail Drawings, Specifications
• Development plan based on key indicators • Preparation of Bill of Quantities
• Evaluation of concepts • Stress Analysis
• Negotiation with authorities and stakeholder
Procurement
Front End Engineering & Design
• Preparation of Tender Documents
• Concept Design/Drawings (Process, Electrical, Automation) • Pre-selection of Bidders
• Evaluation of Concepts • Submission of Tender Documents
• Project Period Planning • Technical / Commercial Evaluation suppliers
• Cost Estimation • Negotiation Contract Awarding
• Budget-tailored Solution

Fuel Infrastructure Solutions to meet your • Site supervision management
targets
To control construction quality
To ensure fuel quality
• Site Supervision Management
• Design & Engineering • Quality control of suppliers
• Site Supervision Management
• Commissioning Services including Site Acceptance Testing To control construction time:

• Technical Service Agreement • Site Supervision Management
• Time Scheduling / Schedule Management
To increase safety
To save energy
• Value Engineering
• Kleopatra® Dynamic Simulation for pressure surge analsis • Kleopatra® Dynamic Simulation to identify optimum oper-
• Kleopatra® CS Control & Automation including Emergency ating parameters

Fuel Shut-off (EFSO) system and fire-fighting functionalities • Value engineering
• Simulator based training
• HSSEMS Consultancy To monitor tightness integrity
• Risk analysis / HAZOP
• TCS® Tightness Control System compliant to JIG/EI
• Technical Service Agreement 1540/1560

To control construction cost

• Kleopatra® Dynamic Simulation to optimize pipe sizing
• Value Engineering
• Cost estimation and control

© 2019 hansaconsult. All Rights Reserved

1 FCuoenlsuDmemptaionnd &

Calculating the actual and foreseen fuel We work side by side with airports and
demand/Consumption is key parameter for the airports developer to determine the most
planing of the aviation fuel infrastructure adequate values based on airport growth
plans and forecast predictions for air travelers
The exercise is very complex due to the various to determine the uplift values
parameters. At hansaconsult we utilize proven
methods that consider all available resources
and data inputs.

© 2019 hansaconsult. All Rights Reserved

Forecast of Fuel Demand Models

Before any detailed estimates or forecast can be made of the fuel demand and peak rate at which fuel must be
delivered into aircrafts it is necessary to obtain as reliable an indication as is possible of the future level of aircraft
activity. Where possible, details of the predicted airport growth levels, both in terms of aircraft movements and
passengers, should be obtained.

As far as possible, the anticipated aircraft mix (at least in terms of narrow bodied and wide bodied aircraft), the
destinations, schedule and typical fuel uplifts should be obtained. If little or no information is available then initial
estimates could be made by comparison of the proposed size of the airport facilities (especially number of runways
and terminals) with existing airports of a similar size and utilization.

A factor that should also be considered is the differing fuel uplifts and ground times for domestic (smaller, but
frequent, uplifts) and international long-haul flights, schedule and charter services (seasonal peaks) and passenger
and cargo aircraft (likely to park in remote apron areas). An assessment should also be made of the possibility of
airlines ‘tankering’ and the likely effects this would have on the volumes.

The Forecast Fuel Demand Models will Provide (as minimum):

1. Average Demand per year.
2. Demand in Peak month
3. Average Uplift.
4. Peak Flow Rate.

An overview for Fuel Burns Trends from International Aviation

2 CFuaeplaSctitoyrage

“Fuel farms are one of an airport’s most critical facilities. They are designed to withstand several days
of demand without receiving external fuel supplies. A failure at these sites could ground aircraft and
consequently lead to damages to passengers”

Sizing of Storage Tanks

Determination of the number and size of storage tanks is usually one of the first design tasks to
be undertaken once initial and long term fuel throughputs have been established.

Total storage capacity is determined from the maximum quantity subsequently settled, fuel cannot be issued from it and therefore
of fuel that needs to be available for a given period, the supply two tanks are the minimum required to ensure a continuous fu-
method and its security, batch size, operational convenience and elling service. For larger depots, a third tank is recommended
future anticipated growth. The storage tank capacity for each so that one tank can be filling and one settling while the third is
airport should be carefully considered as it not only involves a supplying into hydrant or loading refuellers.
considerable capital expenditure but also a significant investment
in working capital cost of stock. Knowing the product supply
rate (either pipeline flow or number of road bridgers, rail tankers,

barges or ships per day), the time taken to fill a tank of a given
size can be determined. During the time a tank is being filled and

“ Fuel supply reliability has a major impact on financial and operational viability of
flights. Airport fuel infrastructure forms a vital part of the fuel supply chain. While at
most airports the fuel facility appears to be adequate, some airports are perceived
to have insufficient or excessive facilities. In case of supply disruptions, insufficient
capacity could result in non-availability of jet fuel. Insufficient storage capacity may
also add pressure on ensuring fuel quality.
© 2019 hansaconsult. All Rights Reserved



3 Hydraulic Simulation

We are committed to a safe and economic handling of fuel.

To control the inherent risks we have developed
the simulator Kleopatra® for operators of fuel farm
and hydrant systems, technical authorities and
insurance companies.

Kleopatra® is globally proven technology to identify
risks and shortcomings and acts as alarm system to
avoid dangerous operating conditions.

More than 25 Years serving
largest Airports around the globe.

Kleopatra® hydraulic studies detects reasons for
pressure surges and pressure losses and as such
provides the basis for a safe and economic design
of your facility.

Either existing or new plant – Kleopatra® presents
on the screen immediately the consequences of
the change of parameters, operating conditions or
configuration. This allows optimizing a facility at
any stage of its life cycle.

“ It should be recognized that hydraulic analysis
requires specialist knowledge, EI-1540.

© 2019 hansaconsult. All Rights Reserved

4 Automation & ControlAutomation Design for a safe and efficient operating tank farm
Competent design ensures economic and energy saving systems in full compliance to
international approved standards and local regulation. Safety in a hazardous environment is the
focus of our solutions.

Safety HIGH AVAILABILITY

Redundant solutions ensure high availability and Robust Control Systems are designed for aviation
fuel facilities and loved by the operators for a user-
uninterrupted control in critical airport operations. friendly clear structure.
Examples to support your Airport Fuel Farm and
Fuel Hydrant System: An intelligent Automation protects plant and
• Emergency Fuel Shut-Off system (EFSO) equipment and reduces the workload of the operator.
• Leak detection system for the fuel hydrant
Site specific requirements are embedded in a
system / Tightness Control System incl DBBV standardized control environment.
• SCADA System including related equipment and
hansaconsult Control Solutions support your normal
fuel facility specific software day-to-day operations and a reliable handling of
• The redundant, fail safe and hot standby PLC emergency situations.

control system including equipment and fuel
facility specific software
• Explosion proof remote I/O panels

© 2019 hansaconsult. All Rights Reserved

“Control & Automation facilities are provided to meet four (4) different type

of requirement:

Emergency Shutdown Reducing the burden on
(ESD) the site operator
Operation and protection
of equipment Enforcement of operating
procedures

5 Stress AnalysisPipe stress analysis provides the necessary technique for engineers to design piping
systems without overstressing & overloading the piping components & connected equipment.
Pipe stress analysis calculates the stress in a piping Our Design tools are all connected, the 3D CAD
system subject to normal operating loads (Static Modeling system is connected with the Stress Analysis
Loads) such as; software, this enable us to efficiently check the piping
system will all components and constrains in place,
1. Weight effect (live loads and dead loads). the analysis results are then fed back to the 3D Model.
2. Thermal expansion and contraction effects.
3. Effects of support, anchor, and terminal Tank Header Stress Analysis reduce destructive
overstresses on the Tank nozzles and shells
movements.
4. Internal or external pressure loading.

And occasional loads (Dynamic Loads) such as;

1. Impact forces.
2. Wind.
3. Seismic loads (earthquake).
4. Vibration.
5. Discharge loads.

Because all piping systems are connected to
equipment such as vessels, tanks, pumps, turbines,
And compressors, the piping stress analysis also
involves evaluation of the effect of the piping
Forces and moments to the connecting equipment. As
the piping stress is controlled by the arrangement
Of the supports and restraints, the scope of piping
stress includes also pipe supports.

Pump station Stress Analysis is essential to protect the
equipment such as pumps, filters, valves,...etc.

Tank Nozzle Connection
Pump Station Header

© 2019 All hansaconsult. Rights Reserved

© 2019 hansaconsult. All Rights Reserved





© 2019 hansaconsult. All Rights Reserved

8 Fuel DepotsThe Logical Model of the Fuel Depots are efficiently modeled into a full 3D
Design layout, where suitability and fit can all be tested in a virtual world.
Integrated Engineering and 3D Design Minimize Schedule times

The Engineering work & Hydraulic Analysis are Reduced site work, concurrent multi-location
translated to Smart Data into the Piping and engineering, higher design efficiency and higher
Instrumentation diagram (P&ID), all components are quality all combine to reduce schedule time.
smart and contains all the design parameters such The ability to react quickly to major project changes
as size, flow rate, medium, Pressure & Temperature is a key parameter in minimizing the project schedule.
ratings and standards, each component has a specific
Tag no. that allow easier identification, the P&ID is
then translated to a 3D Model where all components
are connected and inherit the same properties.

Design Visualization & Communication

The 3D Model allow easier communication with all
the project stakeholder by providing clear picture on
the overall plant, it also facilitate the coordination
with other projects designer/consultant for different
disciplines.

Clash Free Design

An extensive catalogue of predefined parametric
components and object that shape our rich libraries
that has been developed along 40 years is positioned
within the model and then automatically checked for
clashes and Integrity using configurable rules, the end
result is a more Accurate, better quality design that
helps avoid costly changes.
The components that are placed are the actual
component specified and pre-determined with the
client, it identically match the supplier dimensional
and design data.

Business Benefits

Reduce site rework

Higher quality design. the ability to perform multiple
design checks across the entire design eliminates
errors, and enables ‘right-first-time’ engineering.

Accurate materials information eliminates over-
ordering and delays on site due to lack of required
materials or information.

Maximized project quality

Clash checking and integrity checking ensure higher
quality designs and less rework. Database driven
drawing production achieves consistency between
drawings, reports and design data base. Changes
made in the Model is automatically reflected on the
drawings and the bill of material.

© 2019 hansaconsult. All Rights Reserved