Airport Fuel Facility Relocation

Airport Fuel Facility Relocation

Minneapolis, Minnesota

For a PDF version of this case study with photos - click here.

Seneca Companies completed a fuel facility relocation project for the Metropolitan Airports Commission at the Minneapolis-St. Paul International Airport (MSP) Terminal 2-Humphrey. The fuel facility needed to be moved in anticipation of future projected growth at MSP. The project was completed in five distinct areas; A, B, C, D and E.

Due to the sensitivity of working at an airport, all Seneca employees went through MSP’s extensive security process to obtain badges, which were required on site at all times. Additionally, all subcontractors had to have a badged official with their employees. A strict screening process took place prior to anyone entering the job sites.  

Area A
In Area A, the project was focused on modernizing the existing runway 17-35 fueling facility. Seneca’s team added a new double wall steel 12,000-gallon split tank. The tank holds 6,000 gallons of mogas and 6,000 gallons of diesel fuel. Three-inch carbon steel piping was added to the area. Two old lines of piping were pigged, meaning the lines were cleaned of any remaining fuel or residue, filled with nitrogen and sealed for abandonment in place. 

Area B
It was in Area B that the majority of Seneca’s work took place. Below ground, a 25,000-gallon oil/water separator (OWS) was installed to catch any potential runoff as well as a 5,000-gallon double-walled waste fuel tank. Lastly, before aboveground work could occur, Seneca also installed a jet-A tie-in (14’ to 8’), new utilities, storm water drainage (into the OWS) and a large electrical duct bank. The duct bank consisted of several conduits resting on a sand bed, encapsulated by concrete and later soil. Four fueling islands were installed; two for jet-A, one diesel and mogas and one island specifically for offloading fuel into the storage tanks below. The new facility is equipped to bulk load jet-A fuel at 600 gallons per minute (gpm) and diesel and mogas at 150 gpm. 

Area C
Area C had two large 500,000-gallon fuel tanks, a fuel loading facility and a communications building located on it when the project began. All of those structures were demolished over the course of the project. There were two new valve pits installed to connect to existing jet-A fuel lines. Three additional tie-ins, two 8-inch and one 12-inch lines, were also installed to provide alternate fuel routes. This site location has been returned completely to grade and finished with new grass. 

Area D
In Area D, the upgrade was completed to allow fuel to feed differently than it had been. Most of the work in Area D was limited to above ground line tie-ins and piping manifold reconfiguring. There was one 8-inch tie-in and one 12-inch tie-in for fuel at this location. The new piping provided an alternative route for the main terminal’s fuel feed.

Area E 
The work in Area E was done in preparation of a future glycol facility. Glycol is a deicing agent frequently used by aircraft. The work in this area included the installation of storm sewer and water mains. Electrical was stubbed in and ready for use when the new facility is constructed in the future. Area E was then backfilled, concrete slab poured and re-sodded until it can be developed in the future.

The demanding schedule and phased construction requirements required close coordination with the various specialty subcontractors, the engineering team and airport authorities. Work in multiple areas and night operations were required to keep all fuel systems operating while executing the various additions and upgrades.  

Seneca completed the new fuel system facility, upgrade of the existing fuel facility and bulk tank farm modifications without any disruption to airport fueling operations.