Indianapolis Midfield Terminal Thermal Utility Construction
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1 Indianapolis Midfield Terminal Thermal Utility Construction
2 CGCU Background Public Charitable Trust is managed only for the benefit of customers and the community 266,000 customers 3,700 Miles of Gas Distribution Piping Underground Gas Storage & LNG Facilities Oil Operations District Energy (Steam/Chilled Water) Facilities Management
3 Steam Business (regulated) Production capacity 1.9 million lb/hr Plus Waste-to-Energy Steam add l 500 mlb/hr 240 customers, 31 miles of steam piping Chilled Water Business (unregulated) Total CHW Production 74,400 tons for 2008 Main System 47, ,500 (new) Indianapolis Campus Energy - 20, customers, 17 trench-miles of CHW piping Facilities Management (unregulated) Pharmaceutical production and research facilities Steam and chilled water for University Campus BHMM IMC Central Energy Plant
4 Formed in mid-2004 Responded to RFP for operation of IMC Central Energy Plant (CEP) at Indianapolis International Airport (IAA) CEP Operation by BHMM (4/1/06) Production capacity 237 mlb/hr steam (4 boilers, natural gas) 9,100 tons CHW (5 chillers) 12,000 CFM compressed air (3 compressors) 3.0 MWe (3 generators, diesel) 20,000 gpm fire protection system for IMC 12 full-time employees 2 customers Indianapolis Maintenance Center (IMC) 1.2 mm sq ft Indianapolis Midfield Terminal (MFT) 1.2 mm sq ft
5 Indianapolis Midfield Terminal $1.1 billion project 1.2 million sq ft Handle > 8 million passengers/year Reconfiguration of I-70 for easy access District Energy chosen by IAA as heating and cooling solution for new terminal Could utilize existing air permits Offered lower life-cycle cost Utility connector to existing plant vs new MFT plant June 2005 MFT site prep, foundation construction in-progress BHMM (w/cte) asked to evaluate proposed solution
6 Midfield Terminal Project Site Indianapolis International Airport
7 BHMM Evaluation/Proposal Initial IAA Concept Walk-thru tunnel (14 ft OD) All piping pre-fab, carbon steel Walk-in access to tunnel vaults Design Bid (firm price) ROM $42 - $50 million BHMM Proposal Temporary liner-plate tunnel (9 ft OD) Ductile iron for direct buried CHW piping Limited access vaults No tunnel access (piping grouted in-place) Value-Engineer as construction progresses Utilize Target Price Contract ROM $27.0 million
8 Utility Connector Route 2,016 ft tunnel 5,890 ft from CEP MFT U/G, direct-buried piping, electric and communications ductbanks
9 IAA Requirements and Considerations for Utility Connector Design and Construction Utility Connector Piping 8 HTHW psig, 325 F supply, 200 F return 24 CHW psig, 42 F supply, 54 F return FAA approvals for construction Construction Safety Phasing Plan 7460s for construction activity Site Security and Access Plan Runway and taxiways to remain open Zero ground settlement Develop Tunnel Risk Management Plan MBE/WBE participation (15/8/23 req d)
10 Project Team Indianapolis Airport Authority - Owner Aviation Capital Management - OTR Parsons Brinckerhoff Project Engineer BHMM / CTE Project Management and Financing Bowen Engineering General Contractor Midwest Mole Tunnel Contractor PermaPipe, US Steel Pipe Manufacturers
11 Design Development Reengineered tunnel design Liner plates Tunnel Boring Machine (TBM) EPB design Grout and soil conditioner designs Reengineered tunnel piping and manholes Finalized engineering for U/G and arbor piping systems Developed Construction Safety Phasing Submittals to FAA for 7460s Prepared Tunnel Risk Management Plan
12 Unique Aspects of Project TBM Design, Acquisition, and Delivery Bored Tunnel Construction Tunnel Utilities and Thermal Piping Underground and Arbor Piping
13 Tunnel Boring Machine Acquisition, Design, and Delivery Earth Pressure Balance (EPB) design Constant face pressure Steerable Mitigates ground settlement Colorado School of Mines study Disc cutters Soil conditioner maintain muck density of lb/cu ft Grout design adequate compressive strength cure at < 180 F to protect conduits and pipe jacketing Mock-ups and testing Data acquisition and machine control
14 Fully Assembled EPB Tunnel Boring Machine
15 Tunnel Boring Machine Design Colorado School of Mines study Disc cutters Standard vs Special Soil conditioner maintain muck density of lb/cu ft Grout design adequate compressive strength cure at < 180 F to protect conduits and pipe jacketing Mock-ups and testing
16 TBM Drill Head
17 Tunnel Boring Machine Design Data acquisition and machine control Data Acquisition and Monitoring Station TBM Operator Booth Seal Wall and Ring
18 TBM Delivery
19 TBM Drill Head 53 tons
20 Drill Head Placement
21 Bored Tunnel Construction 2,016 ft long x 9 ft OD Liner plate construction 4,750 cu yds material removed TBM Operation Started 6/26/06 Breakthrough 11/6/06 (18 wks) Grouting After installation of ductbank and piping Used ~3,000 cu yds cellular concrete Started 3/29/07 Finished 4/27/07 (4 wks)
22 Bored Tunnel Construction Liner plate construction Resist jacking force of TBM Compressive loading from airfield traffic 20 ft above crown at runway 8,064 liner plates (~104 lb ea) > 56,000 5/8 x 1-1/2 A307 bolts
23 Liner Plate Construction Grout, Soil Conditioner, Air, and Water Piping, TBM Power Cable
24 Bored Tunnel Construction 4,750 cu yds material removed Soil Conditioner Grouting After installation of ductbank and piping Used ~3,000 cu yds cellular concrete Started 3/29/07 Finished 4/27/07 (4 wks)
25 Tunnel Muck into Cart
26 Tunnel Boring Machine Breakthrough 2,016 ft tunnel complete on Nov 6, 2006
27 Tunnel Utilities Communications Conduit 2-2 Steel Fiber Cabling 2-48-fiber cables Thermal Piping Electric Ductbank 12-4 PVC 2-2 PVC
28 Tunnel Thermal Piping 8 HTHW Piping PermaPipe UltraTherm 8 A53 Gr B Smls 100-mil FRP and polyurethane jacket over steel casing 3 mineral wool insulation 24 CHW Piping PermaPipe PolyTherm 24 A53 Gr B ERW Fiberglass jacket, polyurethane foam insulation
29 Thermal Piping at North Tunnel End (EP4)
30 Thermal Piping at South Tunnel End (EP8)
31 Excavation at Tunnel Entrance Jacking Pit (EP4) 55 x 60 x 22 ft deep
32 Jacking Pit (EP4) and Tunnel Entrance Sheet Piling, Bracing, Flooring and Seal Wall
33 Excavation at Tunnel End Receiving Pit (EP8) 30 x 30 x 43 ft deep
34 Receiving Pit (EP8) and Tunnel Exit Sheet Piling, Bracing, Flooring, Seal Wall
35 Drill Head Removal
36 Ductbank, Seal Wall, Piping, Exit Stairs Foundation for South Manhole (EP8)
37 Operation Noodle 8 HTHW Piping Supply & Return - pulled together Max connected load 260,000 lb Min bend radius ft 24 CHW Piping Supply & Return - pulled separately Max connected load 330,000 lb (3 1,000 ft segments) Min bend radius ft Above ground assembly and testing Estimated savings 5 months, ~$1,000k
38 Operation Noodle Above Ground Assembly and Test
39 Operation Noodle 8,000 ft Ready-to-Pull
40 Ramp and Rollers into EP4
41 HTHW Supports and Guides
42 HTHW Sling Supports Pulling Yoke
43 Track Hoe with Pipe Supports
44 HTHW Pipe Pull Complete Pipe Ends at EP4 Pulling Yoke thru at EP8
45 CHW Pipe Pull
46 CHW Pipe Pull Rigging and Supports at EP4 3,000 ft Connected
47 Pipe Tugger Tugger used for Pipe Pulls Protective Shield
48 Tunnel Pipe Support for Pulling HTHW Piping CHW Piping
49 Direct-Buried and Arbor Piping Direct-Buried Piping HTHW - PermaPipe, MultiTherm A53 Gr B Smls 100-mil FRP and polyurethane jacket over steel casing 3 mineral wool insulation CHW US Pipe 24 cement-lined, ductile Iron Not insulated Arbor Piping HTHW - field insulated, 8 A53 Gr B Smls CHW - field insulated, 24 A53 Gr B ERW
50 Direct-Buried Piping into MFT
51 Direct-Buried Piping thru Hotel Vault
52 Direct-Buried Piping In/Out EP4
53 Direct-Buried Piping btwn EP4 and Arbor
54 Arbor Piping
55 Project Timeline Initial Concept to Final Design in ~24 wks (Sep 05 thru Feb 06) Construction took 20 months (Mar 06 thru Nov 07) In-Service Dates CHW 9/24/07 HTHW 10/31/07 (180 F); 12/1/07 (200 F); 1/22/08 (325 F)
56 Cost Summary Cost Utility Connector - $24,350,000 General Construction - ($16,220k) Tunnel and Grout - ($8,130k) MBE / WBE Participation Target 15 / 8 / 23 Actual 13.0 / 10.4 / 23.5 Utility Connector Savings Delivered to Owner >>> $3,859,000 <<<
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