Aircraft refueling method with dispensers and tank trucks

Loading Arms Control Valves Flow Measurement Surge Arrestors

Fueling Systems Loading Terminals System Integrator

Wolfgang v. Meyerinck, Dipl.-Ing. Managing Director Cavotec Meyerinck Germany, Fernwald

Today's aircraft refueling method with dispensers and tank trucks

A critical revue - Time for a change:
Dispenser with hoses

Growing demand for higher fueling flow rates for aircraft: A 380, B 747- 800 and B 787 with increasing passenger numbers more ground support activities for these aircraft
Hose free dispenser

ground times as short as B 737 Frankfurt: ground time A 380 = 165 min

Today's dispenser refueling technology limits refueling flow rates by:

Limitation of the present dispenser performance:
A 380 tank capacity B 787 tank capacity B 747 - 800 tank capacity

~ 230 - 260 m3 fuel

simultaneous refueling with two dispensers occupying both sides of an aircraft for refueling restricts other services under the right wing conventional refueling hoses air operated pressure control pressure consuming venturi and PD-meters high pressure loss today's standard dispenser flow rate ~ 900 gpm (3 400 l/min)

4" hydrant hose

Underwing refueling hoses

Time for a change our targets for the future

Time for a change
increase efficiency increase of fueling flow rate: reach max 1.200 gpm (4.540 l/min) acc. to API increase safety minimize ground times for large aircraft as B787, A380, B747-800 reduce CO2 reduce airport traffic with diesel operated fueling vehicles reduce cost

What can be done: Increase performance by reduction of pressure loss on the dispensing vehicle by:
installation of hose free, solid state refueling arms more efficient "inline" pressure regulating and surge control valve turbine flow meters with electrical signal output instead of PD-meters venturi type with highest pressure loss recovery

Installation of hose free, solid state fueling arms

MEYERINCK fueling arms replace fueling hose
hydrant arms in 5" refueling arms in 3"
Flow velocity
900 gpm / 3400 ltr /min 4" hydrant hose 5" hydrant arm 7 m/s 4,5 m/s 600 gpm / 2270 ltr/min 2 1/2" refueling hose 3" fueling arm 11,5 m/s 8,3 m/s 1200 gpm / 4540 ltr /min 9,3 m/s 6 m/s

Lifting force 25 kg

reduced pressure loss of about 2,5 bar fueling arms have only minimum lifting forces Airbus recommend the use of PANTOGRAPHS on dispensers
(quote from the Magazine "Ground Handling International 12/09") Lifting force 1 kg

hydrant coupler with hoses - lifting force ~ 25 kg hydrant coupler with hydrant arm - lifting force ~ 1 kg fueling arms - less forces to the aircraft single point receptacle MEYERINCK swivel joints: lifetime up to 20 years
Fully balanced hydrant arm

A more efficient & safer pressure control "inline" valve

Main functions:
fuel operated, diaphragm controlled control valve pressure reducing surge shut off venturi control deadman control by system pressure NEW integrated water /solid sensor shut down
Advantage of a separate "inline" control valve: - surge shut off at the inlet of the dispenser and not at the hose end controller - makes pressure reducing function of hydrant coupler obsolete - reduce maintenance on the "piston type" hydrant pressure coupler "Inline" control valve

The hose end controller becomes obsolete

Disadvantages of the hose end controller: - pressure loss about 2 bar! - high surge by closing the Hose End Controller can reach 35 bar in a 2 1/2" hose (surge analysis available) - surge can cause ejection of hydrant couplers and fuel spillage Hose end controller

Experience and references:

Many 1000 control valves of this type in military operation since decades! Hydrant coupler

Accurate and efficient components

turbine flow meter instead of PD-meter venturi type (adjustable) with high pressure loss recovery "Inline" pressure control valve with integrated water / solid sensor - shuts down with water or solids

Turbine meter

Venturi Water / solid sensor control valve

Environmental, safety and health aspects to be enhanced

CO2 Consumption
300.000 kg CO2 year for 100 dispensers 200.000 kg CO2 year for 60 airfield tank trucks total ~ 500.000 kg CO2 / year.
Accident with military aircraft

Increase of safety required

Growing accident danger by increasing traffic of mobile fueling vehicles: an accident on Frankfurt Airport happened between an empty airfield tank truck and an Airbus 340 on 24 December 2008 (damage about EUR 700.000). The tank truck hit a turbine. Luckily no fire developed.
Fully balanced hydrant arm

Increase health protection

less coupling forces during fueling a hose free hydrant arm prevents back injuries as happens with hydrant couplers on 4" hydrant hoses compensation in the US for a back injury (herniated vertebral disk) 100.000 USD

Reduction of traffic and driving cost for fueling vehicles

Data for Frankfurt Rhein /Main airport:
400 aircraft refueling operations / day 100 dispensers ~ 60 tank trucks 14.000 km / year for 1 dispenser 600 driving hours / year for 1 dispenser 3.000 operating hours / year for 1 dispenser A 380 = 165 min ground time between landing and start

Total Expenses / cost for diesel operated vehicles:

An airport like Frankfurt, Rhein-Main/Germany needs in total per year: 1.400.000 km driven distance by 100 dispensers / year (Tank trucks still have to be added). 60.000 hours driving time / year for 100 dispensers EUR 1.785.000,00 cost for fuel / year for 100 dispenser (EUR 700.000,00 cost for fuel / year for 60 airfield tank trucks) The expenses for personnel, maintenance and other operation cost have to be added.

Cavotec Meyerinck made a first step in the right direction:

The worldwide first hose free dispensers with MEYERINCK components
Frankfurt Airport /Germany Amsterdam Schiphol /The Netherlands Gardermoen-Oslo /Norway The hose free dispensers include most of the latest improvements

Shorter fueling times

- Frankfurt ground times : A 380 in 165 min between landing and start - standard dispenser refueling time - new dispenser refueling time : fueling flow rate 900 gpm into A 380, 260 m3 : 76 min : fueling flow rate 1.200 gpm into A 380, 260 m3 : 57 min

possible time savings : 25 % reduction of refueling time

Hose free, direct refueling PANTOGRAPHS since 1979 X

Wide Body Aircraft

Hose free refueling

Wide Body Aircraft, underwing refueling

Tactical Aircraft, hot refueling

X

Tactical Aircraft, In-shelter refueling

Helicopter, hot refueling

2500 fueling and loading arms with 20000 swivel joints since 1979 in operation

The solution: Fueling with gate located diesel engine-free fueling vehicle POV
the solution is a fueling / dispensing unit POV without Diesel engine the Cavotec Meyerinck "POV" is an electrically operated vehicle with batteries POV located permanently close to the gate at the gate the POV can be recharged one (1) POV can serve two (2) gates, or even three (3) gates the electrically operated POV incorporates all the described technical features and advantages

Advantages: Increase of safety: 1.400.000 km less dispenser traffic on airport (example Frankfurt) cost reduction: 17.500 /year for 1 dispenser Reduction of CO2: less 300 000 kg CO2 / year for 100 dispensers (tank trucks not included)

Reduction of traffic on airports also for airfield tank trucks:

MEYERINCK-Hydrant Arm at the airfield tank truck
the airfield tank truck can be refueled from a nearby hydrant pit increase availability of fuel at aircraft remote positions reduces traffic on the airport reduces turn-around-times increases overall safety on the airport
Hydrant arm at a tank truck Pressure reducing and surge shut off valve

reduces CO2 reduces cost Hydrant refueling of airfield tank truck

Thank you for your attention.

MEYERINCK - Trust our Experience, experience the Quality