PROJECT
Our work has included master planning, program management, design and construction. The projects under this program have supported the airlines in meeting current and future fuel demand as the airport undergoes terminal expansion and the fuel delivery system converts to an airport-wide hydrant system.
Capital improvement planning identified the need to move from use of refuelers to a hydrant fueling system. We provided design services for the first hydrant fuel piping installed at the airport, at gates 46 and 47. Construction was timed to take advantage of gate closure for other terminal work.
As plans for a new Terminal 1 progressed, the existing fuel system infrastructure and support facilities within the footprint of the new terminal needed to be relocated. This included construction of a new into-plane fuel operations building and relocating operations to north of the runway, near the bulk fuel storage facility.
A critical component of long-term planning and build-out of an airportwide hydrant fueling system, this project constructed fuel piping and infrastructure for fuel distribution to the west side of the airport and a future hydrant system at gates 48 through 51. The piping provides fuel to the planned West Refueler Loading Facility and the future hydrant system.
Client
SAN Fuel Company
Location
San Diego International Airport
Region
West
Services
Fuel Storage Tanks & Distribution
Fuel Truck Loading & Unloading
Industry
West Refueler Loading Facility
The existing refueler loading facility servicing fuel operations to aircraft was within the planned new Terminal 1 footprint. We designed and built a new refueler loading facility at the west side of the airport to prepare for demolition of the existing refueler loading facility. The west facility included five refueler loading stations designed with a spill containment basin, oil water separator and a filtration system to meet stormwater discharge requirements.
Additional Fuel Storage Tanks
This project, a significant milestone long-anticipated by the fuel consortium, included design and construction of three additional 1 million-gallon jet fuel storage tanks. The tanks provide additional storage capacity to better support fueling operations at the airport. With growing flight frequency and airport expansion, insufficient fuel supply was often encountered during busy months. Fuel supply cycles and unplanned pipeline outages also put constraints on fuel supplies. This fuel storage deficiency caused the consortium to import additional fuel via trucking, which came with a cost premium. This project increased the on-hand fuel supply from under two days to over seven days. This positioned the consortium to be less dependent on supply line deliveries and less vulnerable in the event of an unplanned outage. The project included demolition of existing site pavement and utilities, complex ground improvements and soil stability via deep soil mixing to prevent liquefaction in the event of an earthquake, as well as grading, tank and equipment foundation construction, concrete containment walls, the three 1 million-gallon storage tanks, mechanical fuel piping, electrical controls and instrumentation, fire protection system, containment area liner and aggregate surfacing, coating of tanks and fuel piping, and new pavement.
Once the West Refueler Loading Facility was complete, the existing east refueler load rack could be decommissioned and demolished to make room for the new Terminal 1. Along with demolition of the five refuel loading positions, all underground fuel piping, communications equipment, spill containment pit, and product recover tank were excavated and removed. An above ground oil-water separator, filtration system and fire protection monitors were demolished.
Upsizing Transfer Line Within Casing Under Runway
This project included removing the existing transfer line that fed fuel to the demolished east load rack and installing a larger fuel line to support hydrant fuel operations at the new Terminal 1. The challenge was that the existing transfer line and communications were located within a casing pipe under a very active runway. Extensive planning and preparation, along with unique construction methods, allowed the extraction of existing fuel lines, demolition of the communication conduits, and then inspection and cleaning of the existing casing pipe to make it suitable for housing the new fuel line. The new fuel line and conduit system utilized a casing spacer and was successfully installed within the entire 1,100-foot-long casing pipe.
This critical infrastructure project was a major step in modernizing fueling operations at the airport by enabling the transition to a hydrant fuel system. The heart of the initiative was a new hydrant pump pad, which significantly enhanced fuel distribution efficiency and reliability. Key elements included extensive modifications to two existing above-ground storage tanks to support the new fueling infrastructure. A new power distribution center and facility generator provide resilient, uninterrupted power to fueling operations. Additionally, two fuel transfer lines now connect the pump pad directly to the airfield distribution system, providing fuel delivery to aircraft.
The project also included construction of new load and offload islands/positions, a product recovery tank and a hydrant cart test stand. Extensive pavement work was completed throughout the facility, replacing original pavement dating back to the facility’s initial construction and improving long-term durability and access. Another important component of the project was the installation of an emergency fuel shutoff system at Terminal 2 West gates, which readied these gates for hydrant fuel operations.
Together, these improvements positioned the airport for continued growth, improved operational performance, and enhanced support for the increasing demands of modern air travel.