After the launch of the new refuelling complex, Sheremetyevo became the only airport in Russia with three independent refuelling complexes, which made it possible for air carriers to create a competitive environment, optimise the cost of jet fuel and make their base, operational and economic activities at the airport more efficient.

In accordance with the plans and within the framework of the long-term program for the development of the airport, the system of centralised refuelling of the aircraft of the refuelling complex of AERO-Sheremetyevo JSC (CGS system) began to operate in full.

The capacity of the complex is 1.2 million tons of jet fuel per year, the nominal volume of the tank farm is 20,000 cubic meters with the possibility of increasing to 25,000 cubic meters.

In the project, the Central Refuge Center implemented technical solutions such as a centralised refuelling system and an automatic system of production mechanisms, which allowed reducing the aircraft maintenance time and increasing the safety level of production processes. In general, the new refuelling complex consists of several main sections, united in one common chain for fuel supply of airlines.

Basic fuel storage

To date, the supply of aviation fuel is carried out by rail. To this end, an access road was built, with a length of about 4 km. In the future, it is expected to connect the refuelling complex to the system of main oil product pipelines, which will allow to deliver fuel bypassing the Lobnya station.

The base warehouse supplies fuel by rail transport, receiving it, discharging it into storage tanks, organising the storage of this fuel, recording it and delivering the already prepared fuel through the pumping and filtration station and, after removing the liquid and various contaminants, delivering it to the loading station, which is located on the operational refuelling complex at the airport and in the hydrant system of aircraft refuelling on the airport apron.

The overpass is designed to receive and drain the fuel entering the railway transport. The unit is designed for simultaneous reception and discharge of fuel from 14 tanks (about 800 tons of fuel are discharged in one supply). This trestle is equipped with a system protecting against falls in accordance with the requirements of industrial safety and canopy for work in conditions of precipitation. Here, input quality control is carried out - samples are taken from each tank and make a conclusion about the quality of irrigation and its compliance with the requirements for reception. Next, a permit is issued to receive and dock the drain devices, after which the fuel is drained from the pre-filtration through a special installation and pumped into one of the 4 tanks (intake and consumable).

In the receiving tanks, the process of settling of the fuel takes place, after which samples are taken for quality assessment. According to the results of the control passport is sold. In supply tanks, fuel is delivered through pipelines and pumping stations, it is filtered, water is taken through filters and supplied to the hydrant system or to the loading station. Quality control (airfield) is also carried out in the supply tank. Water is drained and the fuel is checked by benchmarks - it is checked for the absence of water and mechanical impurities. This process is centralised.

Pump-filtration station Divided into 2 sections - receiving and issuing. The reception section includes 3 pump-filtration modules that transfer fuel through a pipeline from rail tank cars and feed / pump it into tanks. The modules are equipped with filter elements with a triple cleaning system. Filtration purity 15 microns. After filtration, the fuel is fed into the reservoirs of the receiving group. In the hangar prepared space for the installation of additional modules to increase capacity. In addition, it is planned to connect to the Moscow transport ring (Transneft pipeline system) to increase the volume of fuel reception and processing.

The production capacity of the receiving section modules is about 600 litres per hour. The capacity of the modules of the dispensing section is about 1200 litres per hour. In this system, the requirements for filtering systems are tightened. Filtration fineness 5 microns. For example, the fineness of cleaning the fuel in the tanker before the supply of fuel to the wing is up to 0.4 microns. The system is automated, but, nevertheless, at the beginning of each shift, staff conducts sampling from filters. This equipment is manufactured by NPO “Agregat” under license from Peco Facet.

After 2 hours after the receipt of fuel in the receiving tank, in accordance with regulatory documents, a sample is taken, which is transmitted to the laboratory. The laboratory is equipped with modern equipment, which allows you to conduct research, to assess the quality of fuel in 11 indicators. According to these indicators, experts make a conclusion on the compliance of the fuel with the requirements of the flight documentation, the requirements of the GOST standards and the possibility of further implementation of aircraft refuelling procedures. The laboratory has a certificate of conformity in the civil aviation system.

At all sites implemented automatic fire alarm systems and automatic fire suppression. The system consists of a 4000 cubic meter water tank, a ring water system, a foam fire extinguishing system and an automatic cooling system. This system is fully automated. Depending on the operation of the fire alarm system (the place of operation), a certain operation algorithm is selected, and the system decides which objects to extinguish, which ones with water, and which with foam. There is a supply of water to the solution at the preparation station, and then through the piping system, the solution is supplied to extinguish the fire. The system works with a capacity of 500 cubic meters of water and 250 cubic meters of foam.

Also, in the event of an alarm in any place, the tanks are cooled. Neighbouring objects automatically begin to cool. For these purposes, fire monitors are provided with remote control by the operator. In addition, everything is monitored with surveillance cameras. All systems are duplicated. The system has 100% reserve for equipment.

The system, which is equipped with the operator, in real time shows all the processes taking place in the refuelling complex, as well as in the fuel supply system at the airport. All images from CCTV cameras on the territory of the refuelling complex, as well as information from the leakage control system are displayed here. Communication between the various sections of the complex and the control room is carried out using fibre optic cables. From here, the control of the fire monitors of the fire extinguishing system is carried out (in addition to automatic control and monitoring on site). On the most hydrant system there are button posts. There are also emergency stop buttons in case of emergency.

Refuelling complex in the airport

At the operational refuelling complex there is a loading station for tankers and their parking. The main objective of the complex is to organize the filling of tankers, conduct aerodrome quality control of fuel, conduct maintenance, work with documentation at the aerodrome. There is also a staff that is directly involved in the process of refuelling aircraft.

The machine comes to the point of loading tankers. The site is equipped with two filling modules, as well as filtering and water sharing devices, a meter and a system for visual control of fuel and physical sampling. The driver pulls up, attaches the filling sleeves, attaches the control system, receives a task to refuel the fuel, and fills the car with fuel. Then the dispatcher gives an indication to the driver with the number of the parking lot and the type of aircraft that needs to be filled. As a demonstration, the Boeing 777-300ER aircraft was serviced by Aeroflot airlines (2,200 liters per minute).

At the parking points near the apron installed special hydrants, the fuel to which is fed through a piping system from the storage tank. The hydrant system CZS "AERO-Sheremetyevo" on the platform of Terminal "B" of the North terminal complex "Sheremetyevo" has 49 columns, which provide the ability to refuel all types of aircraft. Special tanker (unlike normal tanker, the hydrant tanker does not have a tank for storage and transportation of fuel) drives up to the hydrant, attaches the refuelling hose and begins the process of pumping fuel into the aircraft, passing it through an additional filter system. In addition, workers at the hydrant tanker control not only the process of filling the fuel tanks of the aircraft, but also the process of levelling the fuel between the tanks.

The hydrant system of the CZS is equipped with modern systems of emergency protection and automation, control and detection of leaks, gas pollution control in the process chambers, and electrochemical protection against corrosion. The system fully complies with Russian and international safety requirements. From 18 to 19 October 2018, Sheremetyevo held an audit by representatives of KLM Royal Dutch Airlines as part of the mandatory verification of new TZK for compliance with international standards and IATA Fuel Quality Pool rules. The result of the test was the highest score - the green color of the refueling complex of AERO-Sheremetyevo JSC on the official IATA online resource.

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