PIPELINE REPACKING

What is Pipeline Repacking?

Pipeline repacking is the first stage of defueling after all repairs are complete. It is the process of filling 

the pipelines that will be used to defuel Red Hill.

Why is Pipeline Repacking Necessary?

Air in pipelines creates unpredictable flow conditions. Pipeline repacking removes the air which will 

enable the fuel to flow uniformly during defueling. It also provides an opportunity to verify system 

functionality prior to defueling. 

What Precautionary Measures Have Been/Will Be Applied to Repacking?

A Process Hazard Analysis (PHA) was completed to assess risks. Concept of Operations and Operation 

Orders incorporated inputs from industry and regulatory experts. Pre-operation checks to ensure 

system condition. Right-sizing of operating and response personnel to provide sustained support. 

Training/qualification for everyone involved to ensure requisite knowledge. Response/recovery drills 

for worst case scenarios to validate effectiveness of the Integrated Contingency Plan. These measures 

will be incorporated not only for repacking but for all defueling operations. 

UST Gravity Repack – Remaining Air Removed Using Equalization Line

2

Pump Room

Aboveground Storage Tank (AST)

1

2

2

3

3

1

F-24 Pipeline

JP-5 Pipeline

1

2

3

AST Gravity Repack Endpoint – AST and Pipeline Equalization Occurs 

Pump Repack Endpoint – Fill to Last Pressure Indicator Transducer 

(~165K gallons)

(~215K gallons)

Flow Direction

Underground 

Pump House
DEFUELING - TANK MAINS

Two Tanker Hose Connections

2

Pier

F-24 Pipeline

JP-5 Pipeline

1

2

3

Starting Fuel Level in Red Hill Tank

Gravity Flow to Tanker at Pier

Flow Direction

Underground 

Pump House

Tanker

What is Defueling Tank Mains?

Defueling tank mains is the evolution that transfers the bulk amount of fuel from the 14 active Red Hill tanks 

to tanker vessels at Pearl Harbor pier. Fuel is transferred by gravity flow through the Red Hill pipelines. 

How Much Fuel Will Be Transferred?

Starting tank fuel levels vary from 60-212 ft. or 2.5-11.4M gallons. This evolution is designed to transfer fuel 

down to the 10 ft. level or ~120K gallons for all 14 tanks. Fuel transferred during this phase will be ~50M 

gallons of JP-5, ~12M gallons of F-76 and 41M gallons of F-24, totaling ~103M gallons. 

Will Only Tanker Vessels Be Used For Defueling Tank Mains?

Red Hill fuel is planned to go to tankers. Up to 15% could be redirected to refill Pearl Harbor or Hickam tanks. 

Current Fuel Level

10 Foot Level

1

2

3

4

4 Ending Fuel Level in Red Hill Tank
Two Tanker Hose Connections

2

Pier

JP-5 Pipeline

FOR Pipeline

1

2

3

Starting Fuel Level For Flowable Bottoms in Red Hill Tank 

Fuel Drains From Tank Using FOR Line That Ties 

Into JP-5 Pipeline

Flow Direction

Underground 

Pump House

Tanker

What is Defueling Flowable Tank Bottoms?

Defueling flowable tank bottoms transfers the remaining “flowable” fuel from the 14 active Red Hill tanks to 

a tanker vessel at Pearl Harbor pier. This fuel is below the tank’s main fuel line low suction level; the point 

where the primary fuel lines come into each tank. To remove this remaining fuel, a smaller drain line at the 

bottom of each tank is used. 

How Much Fuel Will Be Transferred?

This evolution transfers ~120K gallons of fuel from each of the 14 tanks or 1.68M gallons total.

What is meant by Flowable?

Flowable is the liquid fuel that can be drained from the tanks by gravity. What remains is ~1-2K gallons of fuel 

sludge (non-flowable), that will be removed by entering the tank as part of the cleaning and closure process. 

Sludge Level

10 Foot Level

5

3

4

1

4

Ending Remnants in Red Hill Tank – Sludge Non-Flowable

2

Gravity Flow to Tanker at Pier

5

DEFUELING – FLOWABLE TANK BOTTOMS
Volume 

(Gallons)

Height 

(Feet)

1K-2K

120K

2.4M – 11.3M

<1

10

60 - 212

250

Tank Main 

Fuel Line

Tank Fuel Oil 

Recovery (FOR) Line

TANK SCHEMATIC - FUEL SECTIONS
PIPELINE UNPACKING

What is Pipeline Unpacking?

Pipeline unpacking is the stage of defueling that removes a majority of the fuel in the Red Hill pipelines. 

It involves two steps: 1) Use gravity to transfer fuel to an above ground storage tank (AST) until the 

levels equalize, 2) Use low points outside the underground pumphouse and pumps to pull additional 

fuel from the pipeline and send to an AST.

How Much Fuel Will Be Unpacked?

Unpacking will remove ~185K gallons of F-24, ~250K gallons of JP-5, and ~90K gallons of F-76 for a total 

of ~525K gallons.

After The Lines Are Unpacked Will Any Fuel Remain?

There will be residual fuel that remains throughout the Red Hill pipelines, at bends, low points, and 

valves, etc. that cannot be removed by gravity or pulled out during the pumping step. This residual fuel 

will require maintenance actions to access and remove and will be addressed during a subsequent 

phase.

2

Pump Station

Aboveground Storage Tank (AST)

1

1

F-24 Pipeline

JP-5 Pipeline

F-76 Pipeline

1

2

Gravity Unpacking Endpoint – AST and Pipeline Equalization Occurs 

Pump Unpacking – Removes Remaining Obtainable Fuel 

(~167K gallons)

(~225K gallons)

(~38K gallons)

Flow Direction

Underground 

Pump House

2 2 2
TANK TIGHTNESS TESTING (TTT)

TTT Overview

• TTT is a tank integrity precision test

• Required annually for Red Hill Tanks and Surge Tanks

• Field constructed underground tanks 

• Regulated by Department of Health (DOH) Hawaii Administrative Rules (HAR)

• Program managed by Naval Facilities Engineering Command Atlantic Division (NAVFACLANT)

• Requires no fuel movement or tank pressurization 

Testing Process

• Sensors placed at bottom of tank

• Two day calibration period

• Three consecutive 24 hour tests

• Test to .5 gal/hr leak rate

Additional Monitoring

• Automatic Fuel Handling Equipment (AFHE)

• Automatic Tank Gauging

• Manual

• Gauging

• Trend Analysis

• Soil Vapor Monitoring 

• Ground Water Monitoring

TTT Sensors