Seattle-Tacoma International Airport (SEA) Baggage System Optimization Project

Overview

The Baggage Handling System (BHS) at Seattle-Tacoma International Airport had seven separate Checked Baggage Inspection Systems (CBIS) in operation, with very little redundancy between systems. The Port retained BNP to redesign the system to accommodate 66 Million Annual Passengers (MAP) due to rapid growth. BNP primed the project as the Designer of Record with Gensler, Mazzetti, and Exeltech subcontracted for specialty services.

Energy Efficiency and System Updates

Multiple products were tested for energy cost reduction. The data was compared to the manufacturer’s claims and the airport’s existing equipment to determine long-term energy savings gained. Along with input from the Port’s O&M staff, the BHS equipment specifications were updated. The overall project will remove and replace over 10 miles of conveyor.

Phase 1 Implementation

Phase 1 construction began in March 2017 and concluded in April 2020. It consisted of eight CTX 9800 machines, 28 baggage inspection tables, one temporary MEC, and two temporary sortation mainlines. It utilized 690 drives with distributed I/O controls, run-on-demand energy management, and the ability to bypass the C1 CBIS.

Innovative Controls Architecture

Instead of conventional controls methodology using Motor Control Panels, the distributed controls architecture consists of Motor Power Panels that provide 480VAC power to the drives and Conveyor System Controllers that communicate with the field devices via Ethernet. Conventional pipe and wiring are used for the 480VAC power. All control wiring utilizes Ethernet or low-voltage cabling run in cable trays along the side of the conveyors.

This significantly reduces electrical installation time and labor costs, providing plug-and-play operation for replacement components. With run-on-demand methodology, each individual conveyor runs only when a bag is approaching or the conveyor is occupied. Once the conveyor is clear, the conveyor stops and remains in a ready state. Run time can be configured to any value and can be set by individual conveyor, sub-system, or globally.

Phase 2 Expansion

Phase 2 of the project added four additional EDS machines (with the capability to add four more) to the centralized CBIS. It added fourteen new Bag Inspection Tables (BITs), with the ability to add an additional 16, to the centralized CBRA. It also added four manual encode lines, new sortation to the north concourse, and new mainlines to the south connecting to the south satellite.

Construction of Phase 2 was completed in 2024. Phase 2 introduced over 2,200 new drives with distributed I/O controls and run-on-demand energy management. When completed, four of the seven CBISs were eliminated.

Phase 3 Future Development

Phase 3 aims to connect the south ticket counters to the centralized CBIS, add three additional EDS machines and seven BITs in the centralized CBIS, add four sortation mainlines, two manual encodes, two recirculation lines, two additional makeups in the south bag room, and final connections to the SSAT tunnel and International Arrivals Facility. Phase 3 is designed to eliminate the remaining three CBISs, and construction is scheduled to begin in 2025.