1AirportsHydrant Fueling System
2HANSACONSULT FOR AVIATION HYDRANT FUELING SYSTEMS?WHY CHOOSEHansaconsult stands out as a trusted partner for delivering cutting-edge Aviation Hydrant Fueling Systems.With extensive expertise in engineering, procurement, construction, and commissioning, we provide state-of-the-art solutions that ensure clean, dry, and on-spec fuel delivery to aircraft.Our systems are designed with precision and reliability, meeting the highest standards of safety and operational efficiency to support seamless airport-fueling operations.
ABOUTHYDRANT SYSTEMSHydrant systems at airports form an important part of the overall aviation fuel system, with each segment dependent on proper design, construction, and operation to guarantee asset integrity and fuel quality, ensuring the delivery of clean, dry, and on-specification fuel to aircraft.In the planning of a new international airport hub, the necessity of a fuel hydrant system is unequivocal to meet peak fuel demands during peak periods and to ensure sufficient service time overall. Simultaneous refueling of numerous aircraft at peak periods may occur. Airports and airlines want to reduce aircraft fueling time, while fuel suppliers seek to prevent congestion at refueling stations, and airports strive to decrease traffic on the apron and ramps.The Hydrant System is not only significant at international airport hubs; other considerations beyond the airport's size influence the choice to implement a Hydrant System in airport fuelling operations.In larger airports, the turning point associated with uplift volume may be identified; however, in smaller airports, the turning point is not directly linked to uplift volume.3
44WHAT ISAs per EI-1540 \"A Hydrant system is defined as a buried fuel pipe with associated valves, delivery pumps, filters, drain and venting points, valve chambers, pit boxes and pit valves, instrumentations, control system, cathodic protection system and automated hydrant integrity testing system for the safe and efficient aircraft refuelling”While the definition covers the overall system, it should be noted that the fuel hydrant system planning and design undergoes several stages and could be segregated at certain specific boundaries, this is due several reasons, it could be for engineering, ownership, or budgetary.HYDRANT SYSTEM?
5SYSTEMBOUNDARIESIn general the hydrant system starts at the inlet of the hydrant pumps and ends at the hydrant pit valve inside the hydrant pit box located at each aircraft standsHydrantSystemComponentsTCS®HydrantIntegrityMonitoringBuried fuel pipe systemAssociated ValvesDelivery PumpsDrain and Venting pointsvalve ChambersPit Boxes &Pit ValvesFiltersControl PanelsPower & Instrument CablesCPSystemESDSystem.Instrucontrol System
6CHALLENGES AND IMPACTOF POOR IMPLEMENTATIONBURIED PIPESProper care is essential when designing, procuring, burying, and testing hydrant system pipes installed beneath the airside apron’s thick concrete layer. At Hansaconsult, we ensure meticulous attention to material selection, corrosion protection, and precise engineering to withstand operational pressures and environmental factors. Rigorous testing and quality control during installation guarantee long-term reliability and safety, preventing leaks and ensuring uninterrupted fuel flow in this demanding environment.HYDRANT SYSTEM CHALLENGESAND SAFEGURADS
7Expertise in the installation and construction of hydrant system networks is crucial to expedite the completion of concrete pouring works on the airside apron. At Hansaconsult, we understand that precision and accuracy during this phase are non-negotiable, as the integrity of the system must be guaranteed before the concrete is poured—there’s no room for errors or rework. Our team ensures seamless coordination, rigorous testing, and adherence to best practices to deliver a flawless installation that supports long-term operational reliability.
8DISTURPTION OF AIRPORTThe loss of integrity in an underground fuel hydrant system can have a devastating impact on airport operations.It can lead to fuel leaks, contamination, or system failures, causing delays, operational disruptions, and costly repairs.Such issues compromise the safety and efficiency of fueling processes, affecting airlines, passengers, and ground operations. Ensuring the system's integrity is paramount to maintaining seamless and reliable airport functionality.
9The loss of integrity in buried fuel hydrant pipes can result in substantial financial consequences. Fuel leaks or contamination not only lead to immediate operational disruptions but also incur significant costs for environmental cleanup, regulatory penalties, and system repairs. Excavating and replacing pipes beneath thick airside concrete layers is complex and expensive, often involving extended downtime and labor-intensive processes. Preventative measures and robust system integrity are critical to avoiding these costly repercussions and ensuring uninterrupted airport operations.SUBSTANTIAL FINANCIAL, ENVIRONMENTAL,AND QUALITY CONSEQUENCES
10Many aspects contribute to the overall integrity of the system, the following components are advised to be used as prescribed by the Design Standards (EI-1540).These factors serve as distinct layers of protection to ensure the integrity of the Hydrant System.SAFEGUARDSWE OFFERAt Hansaconsult, we understand the critical criteria that ensure the integrity and optimal performance of Aviation Hydrant Fueling Systems. From design to commissioning, we prioritize every detail to uphold these standards. By implementing best practices and industry benchmarks throughout the entire process, Hansaconsult guarantees reliable, efficient, and safe fueling operations tailored to meet the highest performance requirements.
11DESIGN CONSIDERATIONGeneral design considerations such as system layout, sectioning, minimum depth of cover, system expandability, and commissioning consideration all are vital in achieving a tight system with a maximum life expectancy.
12From an integrity and operation perspective, Hydraulic Analysis is essential from integrity perspective to ensure that the system pressure is correctly calculated taking into consideration the surge pressures that may occur and thus able to specify the correct pipe schedule and wall thickness accordingly.HYDRAULIC ANALYSIS
13PIPE SLOPES, LPD & HPVThe Hydrant System is designed as a JIGSAW design with high-point vents and low-point drains.While the low point drain is an essential component for the Jet Fuel quality, the high point vent is a crucial component for the proper and safe operation of the Hydrant system, assuring its integrity and the efficient functioning of its Tightness Control System.Air in hydraulic systems poses a significant risk as it can lead to higher pressure surges and increased wear on system components. (e.g. Verify valves)
HYDRANT PIPE MATERIAL14Typically, it is recommended to use API 5L Grade B Carbon Steel pipes.The API 5L specifies two levels of specifications, SPL-1 and SPL-2, which guarantee the quality of the pipes. SPL-2 has more stringent acceptance criteria for quality control tests of the pipes at the Mill.
15The pipes shall be coated on the outside and lined on the inside. The interior lining is crucial for maintaining the quality of the jet fuel and also extends the lifespan of the pipe. The external coating system plays a crucial role in maintaining the integrity of the Hydrant system. It undergoes rigorous quality control measures both at the coating factory and on-site following installation.
16Expertise in the installation and construction of hydrant system networks is crucial to expedite the completion of concrete pouring works on the airside apron. At Hansaconsult, we understand that precision and accuracy during this phase are non-negotiable, as the integrity of the system must be guaranteed before the concrete is poured—there’s no room for errors or rework. Our team ensures seamless coordination, rigorous testing, and adherence to best practices to deliver a flawless installation that supports long-term operational CONSTRUCTION PLANSHYDRANT PIPEINSTALLATION
17BRINGING IN THE RIGHT PEOPLE RIGHT EQUIPMENT AND TOOLSAt Hansaconsult, we understand that the success of every project depends on having the right people with the right expertise. We carefully select a team of skilled professionals, including engineers, technicians, and project managers, who bring deep knowledge and experience in aviation fueling systems. Through rigorous vetting and continuous training, we ensure our team is equipped to handle every aspect of the project with precision and efficiency. This commitment to assembling the best talent allows us to deliver exceptional results, meeting and exceeding client expectations.Hansaconsult excels in sourcing and utilizing the specialized tools and equipment required for the construction and testing of hydrant fueling systems. We maintain strong relationships with trusted suppliers and manufacturers, ensuring we have access to the latest and most advanced technology. Whether it’s for precise pipeline installation, pressure testing, NDT, or coating inspection, we carefully select and deploy the right tools for each phase of the project. This attention to detail guarantees efficient, accurate, and safe execution, ensuring the highest standards of quality and performance throughout the construction and testing processes.
18Cathodic protection (CP) is a method used to prevent specific types of corrosion, such as localized corrosion and uniform corrosion attacks.Cathodic protection (CP) prevents galvanic corrosion by counteracting the electrochemical reactions that occur when dissimilar metallic materials come into contact with each other in an electrolytic environment.Corrosion protection is required for steel line pipes used in hydrant systems. The initial stage involves the implementation of a meticulously planned system, culminating in the installation of the Control Panel of the Hydrant System.CATHODIC PROTECTION (CORROSION PROTECTION)
19Hydrant systems must have automated integrity testing, and existing hydrants should undergo integrity testing. Preferably, an automated approach that achieves great sensitivity should be used instead of relying solely on basic pressure testing.AUTOMATED HYDRANT INTEGRITY TESTING SYSTEMS