Opportunity
For the new production facility in Charleston, SC, Boeing required three 35,000-gallon aboveground fuel storage tanks, an Operations, Controls and Laboratory Building, truck loading/offloading stations, refueler vehicle parking, double-walled underground piping, hydrant fuel supply piping in a looped configuration, fuel hydrants, cathodic protection, and emergency fuel shut-off systems
Solution
Mott MacDonald was retained to provide work that included the performance of field surveys to confirm field conditions, verification of the total and spare capacity of the existing airport fueling system, analysis and modeling of the increase in fuel demands, layout of alternative hydrant system routings, analysis of the feasibility of truck fueling off of new hydrant system, and integrated provisions for fuel flushing, circulation, and leak detection.
The project includes the following design elements:
- Inclusion of a laboratory into the fuel farm control building
- Inclusion of a bathroom into the fuel farm Operations/Control Building
- Design of emergency shower/eyewash station system for areas within the fuel operations environment
- Design of a compressed air system supporting the fuel operations facility and the two aircraft fueling positions
- Design of an off-loading station for seal-vac vehicles including, but not limited to, 30 gpm pumps, fuel separator and clay filter
- 480V electrical service in a ground service pit adjacent to each new fuel hydrant pit
- Provisions for receiving alternative fuels (JP-5, biofuels, etc.) and fuel systems designs to accommodate flushing of piping and equipment after use of alternative fuels at fuel truck offloading/loading stations and fuel storage tanks
- Modification of the existing equipment (hydrant fueling pumps, filter separators, control valves, metering, controls, etc.) to accommodate Boeing’s aircraft flushing and fueling flowrate requirements
- Modify/redesign existing hydrant fueling system to accommodate revised aircraft parking positions
- Design of cathodic protection system to protect underground hydrant fueling piping
Outcome
The new Dreamliner assembly plant is one of only two final assembly and delivery points for the Boeing 787. The plant is designed to achieve LEED Silver certification.