San Diego International Airport (SAN) recently completed the first phase of an ambitious hydrant fueling system that will eventually serve all 51 of its existing gates, (and then) 11 more being added in early 2028. As of late July, four gates in Terminal 2 were already using the new system, with 17 gates in the new Terminal 1 slated to be outfitted to use it this fall.
“It will take several more years to add the hydrant fuel system to all of our gates, but we think it will be worth it in the long run,” says Angela Shafer-Payne, the airport’s vice president of development.
The airport self-funded the first six installations and related infrastructure for $50 million. The airline fuel consortium at SAN will pay to install the system at the remaining 58 gates. Those costs are estimated at $200 million.
Safety, operational efficiency and sustainability are the main benefits that inspired SAN to initiate the change in fueling strategy. “With this project, we are going to be able to remove 50 fuel trucks that today are continually running around the airfield,” Shafer-Payne explains. “Any time we can avoid some of that vehicular traffic, that is a bonus.”
Practically speaking, using a hydrant fueling system is a more efficient way to transport fuel from the storage tanks to aircraft. From the airlines’ perspective, it significantly reduces turnaround times, which also benefits passengers. “Another advantage is reduced cost to the airlines, as there is less infrastructure to maintain,” adds Shafer-Payne. “And with fewer trucks, the airport’s carbon footprint will be reduced.”
Initial planning for a hydrant system began in 2016, when SAN started the development process to build a new terminal. “As we were discussing the terminal project, we felt like the time was right to take a hard look at a hydrant fueling system, since several sections of pavement around the gates would be torn up anyway,” Shafer-Payne relates.
Before any of the new hydrant system could be activated, however, the fuel distribution infrastructure needed several complex improvements. For engineering, design and construction support, the airport turned to Burns & McDonnell, a familiar project partner.
“To support a new hydrant fuel system and prepare for future demand, the airport needed a complete overhaul of its piping distribution system, increased fuel storage capacity and a new pumping system,” explains Tyler Curry, projects manager for Burns & McDonnell. “Coordinated with other airport capital improvement projects, the first hydrant system was successfully installed and activated at gates 46 to 51. After consulting with the airport and the various airlines, it was decided that gates 48 to 51 would be the first to implement the new system.” Those particular gates, located at the end of Terminal 2, are primarily used by international airlines operating jumbo jets with large fuel reserves—conditions that will provide a good test of time saved by the new hydrant system.
Piping needed to support the system at gates 46 to 51 was installed from 2018 to 2021, since most of those gates were already going to be out of commission for other construction projects. With gates 48 to 51 already activated, 46 and 47 are scheduled next (in spring 2026).
Passing the Torch
 facts&figures
Project: Hydrant Fueling System Location: San Diego Int’l Airport Initial Cost: $50 million (for first 6 gates & related infrastructure such as pad system, piping, tank upgrades, etc.); additional $3.5 million for inspection over course of entire project going forward Funding: Airport capital improvement funds Piping Installation: 2018- 2021 Initial Infrastructure Installation: Dec. 2018 Initial Implementation of Hydrant System (gates 48-51): June 2025 Est. Cost for Implementation at Remaining Gates: $200 million Funding: SAN Fuel Total Scope: 51 gates over next 3 yrs.; 11 more gates being added in early 2028 Design-Builder: Mechanical/Civil Work: Piping Installation: Murray Co. Electrical Work: Neal Electric Power Distribution Center: Custom Controls Modifications to Oldest Storage Tanks: Paso Robles Helical Pile System: Keller North America Hydrant Fuel System Operator: Menzies Aviation Fuel Consortium Members: Air Canada; Alaska Airlines; American Airlines; British Airways; Delta Air Lines; Federal Express; Frontier Airlines; Hawaiian Airlines; JetBlue Airways; Lufthansa; Southwest Airlines; Spirit Airlines; Sun Country Airlines; United Airlines; United Parcel Service; WestJet Project Benefits: Faster turnaround times for aircraft; more environmentally friendly fueling process; fewer airfield safety hazards; enhanced operational capabilities |
The first segment of the hydrant system was financed by the airport itself. During that period, the airlines had an advisory board that worked closely with airport officials on fuel-oriented projects. But in 2020, a formal fuel consortium, SAN Fuel, was created that then supervised and financed all future fuel distribution and improvement projects going forward. Burns & McDonnell continued as the chief engineering consultant and design builder for the hydrant system project, reporting to SAN Fuel.
“For any airport, having a modern infrastructure to meet its fuel needs is imperative,” says Jonathan Flores, chairman of the consortium. “At SAN, that was the main reason we went to a more formal consortium comprised of the top airlines at the airport. While it is a complex arrangement, it remains a cooperative and well-functioning one. Implementing a reliable fuel hydrant system necessitated several complementary infrastructure projects to enhance the overall efficiency of fuel delivery.”
The heart of this project was installation of a new hydrant pump pad, which significantly enhanced fuel distribution efficiency and allowed activation of the hydrant fuel system at gates 48 to 51. Although these are the first gates to use the new hydrant fuel system, ongoing and future projects will allow all terminals to use the system to fuel aircraft at the gates.
Other Upgrades
Along with the new hydrant pump pad, the rest of the project modernized and upgraded the bulk storage fuel facility to prepare the hydrant system for activation. Key elements included:
- extensive modifications to two existing above-ground jet fuel storage tanks;
- installing two fuel transfer lines connecting the new pump pad to the airfield fuel piping distribution system;
- a power distribution center and generator for the fuel facility to ensure resiliency and uninterrupted power for fuel operations;
- new load and offload positions for fuel trucks at the fuel facility;
- a product recovery tank for additional retention and reuse of jet fuel captured from operations;
- a hydrant cart test stand for calibrating carts used at gates for fueling;
- an emergency fuel shutoff system installed at gates 46 to 51; and
- replacing pavement at the fuel facility.
Another vital aspect to improving the overall fuel-distribution system was designing and constructing three additional 1 million-gallon jet fuel storage tanks. “With the expansion of the airport and the subsequent increase in flights, fuel shortages were often an issue, especially during busy months,” Flores explains. “As a result, the consortium had to bring in additional fuel via trucking, which increased our costs and put the operation at an unnecessary risk of facing delays.”
Besides adding three new tanks, the consortium also increased its offsite storage capabilities. “Overall, we now have more than seven days of fuel on hand, as opposed to only the two-day supply we had before,” Flores adds.
Plans for More Hydrants
The next gates set to receive the new hydrant system are located in SAN’s new Terminal 1, and are scheduled to open early this fall. Following complete buildout of the new Terminal 1, the project team will begin targeting the remaining gates at Terminal 2 for the new hydrant fueling system. The target for all gates to be outfitted is mid-2028.
Installing the rest of the hydrant fuel system will not be a continuous project. “We expect to have starts and stops because we can’t have more than a couple of gates down at a time,” says Shafer-Payne. “We have to work around other airport projects, such as replacing aging boarding bridges. We have to do that first at a given gate, before we can add the hydrants at that gate. Furthermore, this airport is especially busy during the holidays, so we try to keep open as many gates as possible during that period.”
SAN Fuel will manage and fund the rest of this project, as well as future fuel programs. Shafer-Payne estimates that completing the hydrant system over the next three years will cost approximately $200 million.
“It can cost up to $100,000 to install the pad and pump for each gate,” Flores advises. “For this program, most of the money will come out of our capital improvement fund. Fortunately, SAN Fuel is financially robust, backed by industry-leading airlines with substantial resources and long-term investment opportunities. We do not anticipate this being a big issue.”
The airport has allotted $3.5 million in its capital program for inspection over the course of the entire fuel program. “We consider this a tenant project,” says Shafer-Payne, noting that the airport charges only a fuel flowage fee, which provides a very small revenue stream.
Good News on the Environmental Front
The project team was pleasantly surprised by the process to secure the required environmental approvals for the hydrant fuel system. Because SAN is located in a coastal zone, the airport has to submit all projects to the California Coastal Commission. “For this project, they actually gave us an exemption because the work was not going to involve a height or visual issues,” Shafer-Payne notes.
Enabling projects included installation of an isolation valve vault.
In fact, under the California Environmental Quality Act, the project is considered a benefit to the environment because it is removing fuel trucks from the airfield. “All in all, this was one of the easier projects to get approved,” Shafer-Payne remarks.
Currently, the airport’s fixed base operator, Signature Aviation, offers sustainable aviation fuel (SAF) to general aviation aircraft. “However, if airlines or private companies want to utilize SAF in the future, the new fuel distribution system could be used for that purpose,” she adds.
System Management
Menzies Aviation manages the day-to-day operations of the new hydrant fueling system and fuel storage facility for SAN Fuel. “They basically run the fueling operation, but keep me informed of any operational issues, whether routine or more significant, ensuring seamless communication and oversight on behalf of the consortium,” Flores says. “If any operational issues arise, such as equipment not performing as expected, the operators promptly notify me, and I coordinate with the appropriate parties to ensure timely resolution.”
Shafer-Payne describes the airport’s relationship with the consortium as seamless. “We communicate with them several times a week, and keep them informed of the status of those projects that may affect the airlines’ fuel operations,” she says. “And if they have an issue with anything, they are encouraged to let us know. This new hydrant fueling system is certainly a complicated project, but once we are finished, I am confident that all of our stakeholders will be very pleased.”
KLM and other international carriers are the first to benefit from the new hydrant fueling system.
Although the new hydrant system only has been in place since June, Shafer-Payne already has received positive feedback from British Airways. “They have a twice daily flight to London. In the past, it would take four fuel trucks to fuel the jumbo aircraft they use for that long flight. Our new hydrant system considerably reduces the fueling time,” she reports.
Looking out the window at the airfield, Shafer-Payne sees fewer fuel trucks scurrying around gates 48 to 51. “In the future, as more gates get this hydrant system, we won’t have to continually ask airlines to reposition their ground support equipment, as is the case now,” she adds. “That will benefit everyone.”
