HomeMy WebLinkAbout08.d.1)b) Minutes-Engineering & Operations Committee 11-16-168.d.1)b)
Central Contra Costa Sanita Dist ict
SPECIAL MEETING OF THE
CENTRAL CONTRA COSTA
SANITARY DISTRICT
ENGINEERING & OPERATIONS
COMMITTEE
MINUTES
Wednesday, November 16, 2016
1:30 p.m.
2nd Floor Conference Room
5019 Imhoff Place
Martinez, California
Committee:
Chair Paul Causey
Member Tad Pilecki
Guests:
Sanjay Reddy, Black and Veatch (left after Item 3.)
Staff:
General Manager Roger S. Bailey
Deputy General Manager Ann Sasaki
Director of Engineering and Technical Services Jean -Marc Petit
Capital Projects Division Manager Edgar Lopez
Senior Engineer Craig Mizutani
Accountant Am al Lyon
Senior Administrative Technician Cindy Granzella
BOARD OF DIRECTORS:
TAD J. PILECKI
President
PAUL H. CAUSEY
President Pro Ten2
.MICHAEL R. MCGILL
JAMES A. NEJEDLY
DAVID R. WILLIAMS
PHONE: (925) 228-9500
FAX: (925) 676-7211
www.centralsan.org
1. Call Meeting to Order
Chair Causey called the meeting to order at 1:33 p.m.
2. Public Comments
None.
3.* Further review of draft Position Paper to authorize the General Manager to
execute a professional engineering services agreement for the Solids Handling
Engineering & Operations Committee Minutes
November 16, 2016
Page 2
Facilities Alternatives Evaluation and Predesign [continued from November 8,
2016 meeting]
Mr. Petit distributed a revised draft position paper to replace the one that was in
the agenda materials (attached). The Committee reviewed and provided
feedback to staff to clarify the position paper. Chair Causey and Member Pi
item 4.
(Committee Handout)
Central Contra Costa Sanitary District
BOARD OF DIRECTORS
POSITION PAPER IL,J1
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
Submitted By:
Initiating Dept./Div.:
Nathan Hodges Engineering and Technical Services/
Associate Engineer Capital Projects Division
REVIEWED AND RECOMMENDED FOR BOARD ACTION:
C. Mizutani — Senior Engineer
D. Frost — Senior Engineer
E. Lopez — Capital Projects Division Manager
JM. Petit — Director of Engineering and Technical Services
Roger S. Bailey
General Manager
ISSUE: Board of Directors' (Board) authorization is required for the General Manager
to execute a professional engineering agreement in an amount greater than $100,000
and for budget transfers over $500,000 in the Capital Improvements Budget (CIB).
BACKGROUND: The CIB Treatment Plant Program includes several projects
associated with the solids handling facilities at the District. These projects are as
follows:
• District Project 7286: Centrifuge and Cake Pumps Upgrades
• District Project 7312: Ash Facilities Improvements
• District Project (TBD): Wet Scrubber Replacement
In addition, the Capital Improvement Plan (CIP) includes another project associated with
the solids handling facilities at the District:
• Solids Conditioning Building Seismic Improvements
One of the key findings of the Comprehensive Wastewater Master Plan (CWMP) is
that the District's multiple hearth furnaces (incinerators) are in good physical condition
due to good operation and maintenance practices. However, related solids handling
support facilities require upgrades or replacement to maximize the useful life of the
incinerators. Additionally, the incinerators themselves need to undergo significant
seismic retrofits to be structurally sound, as they are not designed to withstand a major
earthquake. As stated above, several projects have been identified in the current CIB
and CIP that are associated with solids handling. In addition to those projects, the
CWMP has identified additional solids handling improvements, which include the
following:
Page 1 of 10
POSITION PAPER
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
• Possible Lime Reduction
• Sludge Blending and Storage Improvements
• Incinerator and Solids Conditioning Building Seismic Upgrades
The issues to be addressed in the solids process areas are complex and
interdependent; decisions made for one process area will have an impact on other
processes. Although there are several drivers for the proposed work, including
addressing aging infrastructure and reducing plant energy demands, compliance
assurance is paramount.
For those reasons, District staff assembled a scope that encompasses all these
elements associated with the solids handling facilities and the incinerators into a single
project, namely the Solids Handling Facilities Alternatives Evaluation and Predesign
Project (the Project). This approach will be more efficient and effective in resolving
concerns and challenges with the Solids Conditioning Building (SCB) and associated
equipment and essential processes dealing with solids handling, processing, air
emission control equipment, ash disposal, as well as energy production.
Priority ranking for these projects comprising the Project ranges from very high to
critical.
This Project will address four major drivers outlined in the Comprehensive Wastewater
Master Plan: 1) replacing aging infrastructure; 2) capacity limitations; 3) regulatory
compliance; and 4) sustainability and energy.
Driver 1 - Replacing Aging Infrastructure: The majority of the solids handling
facilities are in the SCB, which was built in the 1970's as part of the Phase 5A project,
along with the rest of the plant expansion following the enactment of the Clean Water
Act in 1972. Some of the equipment is over 40 years old and nearing the end of its
useful Life. The Centrifuges and associated cake pumps are roughly 25 years old and
in constant need of maintenance, and critical centrifuge components are shipped back
and forth to Houston, Texas. The sludge blending tank and emergency tanks are
refurbished anaerobic digesters which were constructed in the 1950 to 1960's. These
repurposed tanks offer volume to store and blend primary and thickened waste
activated sludge but are not the appropriate size. The available volume is too large for
daily operation which often creates a septic sludge condition not conducive to
dewatering and requiring lime for pH adjustment.
The ash handling system also needs improvements to update aging equipment and
meet current regulations.
Page 2 of 10
POSITION PAPER
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
The wet scrubber is an older technology which may have contributed to a recent notice
of violation (NOV) from the Bay Area Air Quality Management District (BAAQMD), as
expanded upon under Driver 3 below. At best, the current system can only marginally
meet current air emission requirements. With upcoming pending air regulations, the
existing wet scrubber will not be able to meet more stringent emission regulations;
therefore, it must be replaced with more effective and energy efficient technology that
uses less water and power.
Driver 2 - Capacity Limitations: As presented at the June 16, 2016 Board
Workshop # 2 on the CWMP, the incinerators have some challenges associated with
capacity. Lime is currently being added to the sludge blending tank for multiple
reasons (pH adjustment, copper sequestering, and prevention of clinker formation in
the incinerators). However, the addition of lime adds volume and uses needed
capacity from the incinerators and other processes like the dewatering equipment. The
incinerators have a limited set capacity which cannot be exceeded under the Title V
permit. This project will research reducing and possibly eliminating lime addition to the
solids process. This has a direct impact on O&M cost, centrifuge performances and
capacity, and furnace capacity.
Driver 3 - Regulatory Compliance: The following regulatory compliance challenges
need to be addressed:
1. Determine optimal approach to comply with BAAQMD Draft Air Toxics
Regulation 11, Rule 18. The draft rule was released in October 2016, with
tentative adoption scheduled for May 2017. The new regulation can potentially
require the District to upgrade the existing air pollution control system in the
next few years to reduce toxic air contaminant emissions, and to notify the
public if the Treatment Plant's cancer risk is greater than 10 in a million, based
on the results of a health risk assessment (HRA).
2. Compliance with Existing 129 Sewage Sludge Incinerator (SSI)
Regulations:
a) Eliminating use of emergency bypass damper of the waste heat
boiler. The new 129 Sewage Sludge Incinerator Regulations (129
Regulations) limit the bypass damper operation and require each bypass
opening event be reported to BAAQMD. Since the effective date of the
129 Regulations in March 2016, the District has had three reportable
compliance activities, one of which resulted in a violation of this new
requirement. A new wet scrubber system will help ensure continuous
Page 3 of 10
POSITION PAPER
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
compliance with the existing 129 Regulations and can be designed to
treat emissions that would normally bypass the incinerators' waste heat
boilers and be released directly into the atmosphere without any
treatment.
b) Significantly reduce or eliminate daily caustic injection to reduce
cost of compliance with hydrogen chloride (HCI) emissions. The
existing wet scrubber for Furnace No. 2 is ineffective at treating HCI
without caustic addition. The ongoing caustic chemical cost is as much
as $400,000 per year. New scrubber equipment is designed to reduce
HCI will meet the standard with fewer chemicals. This will reduce O&M
expenses, and wilt be more efficient with power and water usage.
c) Track incinerator -related improvements to avoid triggering
incinerator reclassification. More stringent air pollution emission
requirements are triggered by the 129 Regulations when the aggregate
cost of improvements on certain incinerator -related improvements
reaches 50 -percent of the original incinerator facility construction cost.
d) Enhanced limits on visible emissions from ash handling: The ash
loading facility is located outdoors. District staff has made recent
improvements to limit fugitive visible ash emission during the ash loading
process (two truckloads weekly). However, this operation would be more
controlled if the loading happened in an enclosed facility where the trucks
could drive in. The emergency sludge loading building was constructed
to allow for dewatered solids storage and loading in the event the
incinerators where out of service. However, it is not used on a routine
basis. Modifications could be made to the building to relocate the ash
loading inside this facility while keeping the original intent intact.
3. Determine air pollution control sidestream impacts on compliance with
the District's National Pollution Discharge Elimination System (NPDES)
permit. It is likely that scrubber water sidestream treatment may be required to
remove increased metals loads diverted to the liquid stream when a new
scrubber with higher metals removal efficiency is installed. One metal of
concern is mercury, because the District has an existing total maximum daily
load limit for mercury discharge to Suisun Bay.
4. Compliance with the new PM 2.3 Requirements: The new air emission
equipment will need to be selected to be flexible for complying with future air
Page 4 of 10
POSITION PAPER
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
emission requirements such as the new PM2.5. BAAQMD was recently
declared as non -attainment for PM2.5. Over the next three years, BAAQMD
will be examining which existing sources need additional controls to bring the
BAAQMD into attainment. The District's existing wet scrubbers were not
designed to control PM2.5.
5. Compliance with Building Code Seismic Regulations: The District
conducted a seismic report of its facilities in 2009. Several seismic design
needs and code deficiencies were identified in this report. Projects needed were
outlined and prioritized. Two of the higher priority projects are now either
completed (Headquarters Office Building Seismic Upgrades), or in the
construction stage (Pump and Blower Building Seismic Upgrades). One of the
next critical facilities identified is the SCB, as it does not meet current building
code and seismic standards. This building houses both staff and critical
equipment necessary for the operation of the Plant (solids handling, dewatering,
incinerators, power generation units, steam system, and other ancillary and
electrical equipment). The incinerators are not designed to current seismic
design standards and must be seismically evaluated if the District plans to use
them for at least the next decade, and possibly beyond. These seismic
requirements and retrofits will be evaluated and included as part of this project.
Driver 4 - Sustai nabi l itv and Energy Optimization: The following operational and
energy improvements will be addressed:
1. The sludge blending tank currently uses pump mixing. However, because the
tank was originally a digester, the tank geometry and associated pump mixing
equipment is not optimized. A smaller tank design using modern and more
efficient mixing equipment will reduce O&M costs by reducing chemical addition
(lime and polymer) and energy consumption. This will also reduce labor costs
associated with operating and maintaining this equipment.
2. The existing solids dewatering process includes progressing cavity pumps (with
sludge grinders), four centrifuges and associated cake pumps, piping and
controls that feed the two incinerators at two separate locations each, or four
separate locations in total. New equipment will reduce O&M costs by reducing
the high maintenance currently required by this equipment, but will also reduce
polymer and power consumption by an estimated 50% or more. New
centrifuges can effectively produce higher cake solids with improved centrate
quality (higher solids capture) while using half the connected horsepower to run
the equipment.
Page 5 of 10
POSITION PAPER
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
Project Approach
As District staff considered the Wet Scrubber, Centrifuge and Cake Pumps, and Ash
Handling projects as part of the CWMP, it became apparent that a more
comprehensive look at the entire solids process was necessary to properly design
replacement or improvements. Therefore, staff has recommended combining the
predesign scope of these projects, along with other related CIP projects to determine
the optimal approach in proceeding with current and future solids handling projects.
The new project will be titled "Solids Handling Facilities Improvements Predesign" and
will be included in the current Fiscal Year (FY) 2016-17 CIB. This newly defined project
will include the pilot testing of the air emission control equipment (new wet scrubber) to
determine the proper selection of the new technology. This pilot test will not only
validate the equipment selection and associated design criteria, but will also determine
the best technology to optimally treat the liquid steam generated from that process as it
removes impurities, and metals from the air stream. This will be a critical design
element since the District wishes to avoid creating any inadvertently undue burden on
the liquid treatment process, which has its own permit requirements (NPDES). Pilot
testing will be a critical component of the evaluation work.
Air pollution control (APC) equipment testing wilt be important in determining
performance requirements for equipment, establishing expected removal efficiencies,
and determining whether or not sidestream treatment is required and confirming the
proper sidestream treatment technology. This information will help decide the
appropriate equipment and installation timing, such that the District remains in
regulatory compliance.
The project will include a significant amount of predesign work to ensure the
appropriate improvements are made to meet current reliability and regulatory needs,
and remain compatible with the Tong -term vision identified in the CWMP. Evaluations
will be conducted to establish the design parameters for each solids process and
associated equipment. Table 1 below outlines the major project elements to be
addressed under this project to achieve compliance assurance:
Page 6 of 10
POSITION PAPER
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
Table 1: Project Elements and Drivers
Element Project
# Elements
Incinerator Air
Pollution Control
1 Equipment
(including wet
scrubber pilot
testing)
2
Replace
Dewatering
System
(centrifuges, cake
pumps, etc.)
Optimize Sludge
3 Blending and
Storage Facilities
Engineering
Evaluation of
4 Health Risk and
Alternatives
Analysis
5
6
7
8
Lime Reduction
Pilot
Ash System
Upgrades or
Relocation
Solids
Conditioning
Building
Incinerator Seismic
Upgrades
Driver(s)
10%
Design
Driver 3: Regulatory Compliance Yes
Driver 1: Replacing Aging
Infrastructure, and
Driver 4: Sustainability and
Energy Optimization
Driver 4: Sustainability and
Energy Optimization
Driver 3: Regulatory Compliance
Driver 2: Capacity Limitations, and
Driver 4: Sustainability and
Energy Optimization
Driver 1: Replacing Aging
Infrastructure, and
Driver 3: Regulatory Compliance
Driver 3: Regulatory Compliance,
and
Driver 4: Sustainability and Energy
Optimization
Driver 4: Sustainability and Energy
Optimization
30% Benefits
Design
Compliance with
Yes Air and Water
Regulations
Yes Yes
Yes Yes
Pilot
Study
Pilot
Study
No
Reliability,
replacement of
aging equipment,
addressing a lack
of spare parts
availability.
Improvement of
efficiency and
lowered energy
cost
Reliability,
consistent
dewatering and
reduction of O&M
Costs
Compliance with
Air Regulations
Reduction of O&M
costs and delaying
No incinerator capacity
deficiency
improvements
Compliance with
Air Emission
Regulations, and
replacement of
aging equipment
Compliance with
current
Building/Seismic
Code.
No Improvement for
Worker's Safety,
and improvement
of operational
resiliency
Compliance with,
current
Building/Seismic
Code.
No improvement for
Worker's Safety,
and improvement
of operational
resiliency
Yes No
Yes
Yes
Page 7 of 10
POSITION PAPER
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
District staff issued a Request for Proposals (RFP) on September 1, 2016 to the
engineering consulting community and received three proposals (Black & Veatch,
CH2M, and CDM Smith). Engineering and Operations staff evaluated the proposals
and interviewed the consultant teams. Black & Veatch (B&V) had the highest total
score and is considered the best overall project fit. The agreement with B&V will
include the elements listed in Table 1 which consist of preliminary design (10%
complete) for all project elements, pilot testing design and support, cost estimates, and
predesign work of key project components to a 30% level of design completion.
District staff plans to issue future RFP(s) for final design services and possible
construction support services. At this time, staff anticipates the wet scrubber and
related air pollution control improvements, centrifuges and cake pumps, and sludge
blending work wilt proceed to 30% design and likely move forward to full detailed
design. Not all components of the project may be constructed at the same time
depending on the outcome and recommendations from the preliminary design efforts.
FINANCIAL IMPACTS: The total project cost estimated is shown in Table 2 below:
Table 2: Project Cost Estimates
Project Elements
1 Incinerator Air Pollution Control
Equipment $30 Million FYs 16-18 FY 18-19 FYs 19-21
Pilot Testing of Wet Scrubber,
Lime Reduction and Polymer $850,000 FYs 16-18 TBD TBD
Optimization
2 Replace Dewatering System $12.4 Million FY 18-19
(centrifuges, cake pumps, etc.) FYs 16-18 FYs 19-21
3 Optimize Sludge Blending and
$2.9 Million
Storage FacilitiesFYs 16-18 FY 18-19 FYs 19-21
4 Health Risk Assessment (HRA)
Modeling $200,000 FY 16-17 TBD TBD
Proposed Implementation Schedule
Total Project Cost Preliminary Final Design Construction
Estimate (1 Design
9
5 Lime Reduction to reduce
loadings to furnace (Monitor
Heavy Metals — Copper,
Selenium in Centrate and Final
Effluent)
6 Ash System Upgrades or
Relocation
7 Solids Conditioning Building
Seismic Upgrades
8 Incinerator Seismic Upgrades
$150,000
$2.0 Million
$13.5 Million
$5.0 Million
FY 16-17 TBD TBD
FY 16-17 FY 18-19** FYs 20-23**
FY 16-17 FY 18-19** FYs 20-23**
FY 16-17 FY 18-19** FYs 20-23**
Total Estimated Project Cost $67.1 Million
(*1 Project Cost Estimate in 2016 $ from the CWMP Draft CIP -- November 10, 2016
(**} To be confirmed based on preliminary design recommendations
Page 8 of 10
POSITION PAPER
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
The B&V agreement costs are estimated to total up to $2,000,000, which is about 3% of
the estimated total project costs. The projects funding for this predesign effort are
included in the FY 2016-17 District Budget, with the following budgets:
Table 3: Project Funding Sources
DP No
7286
7312
7348
7315
Project Name
Centrifuge and Cake Pumps Upgrades
Ash Facility Improvements
Wet Scrubber Replacement
Applied Research and Innovations
CIB Contingency
Totals:
FY 2016-17 Budget
$500,000
$800,000
$400,000
$150,000
$150,000
$2,000,000
Page
120
128
143
130
(*) As of October 30, 2016, $ remain in the FY 16-17 contingency before applying the requested
amount to this project.
The budgets listed above in Table 3 will be transferred from existing District projects to
fund the consolidated new Solids Handling Facilities Alternatives Evaluation and
Predesign Project. The total project spending this fiscal year is expected to reach
$1,700,000, which includes consultant fees, pilot costs, and District staff time. The
remaining $300,000 is forecasted to be paid under the following fiscal year budget as
this project will straddle two fiscal years. This agreement will help develop a more
detailed predesign estimate for future construction costs to be included in the District
budget.
ALTERNATIVES/CONSIDERATIONS: An alternative would be not to proceed with the
agreement, which is not recommended because the action would delay staff's ability to
implement the projects intended to meet existing and upcoming new regulatory
requirements.
STRATEGIC PLAN: The Project aligns with the following District Strategic Plan goals:
• Goal 2 — "Strive to Meet Regulatory Requirements"
• Goal 3 — "Be a Fiscally Sound and Effective Water Sector Utility"
• Goal 5 "Maintain a Reliable Infrastructure"
• Goal 6 — "Embrace Technology, Innovation, and Environmental Sustainability"
COMMITTEE RECOMMENDATION: The Engineering and Operations Committee
reviewed this project at the meeting on November 16, 2016, and recommended
approval of this project and agreement.
Page 9 of 10
POSITION PAPER
Board Meeting Date: December 1, 2016
Subject:
AUTHORIZE THE GENERAL MANAGER TO EXECUTE A
PROFESSIONAL SERVICES ENGINEERING AGREEMENT WITH BLACK
& VEATCH CORPORATION FOR THE SOLIDS HANDLING FACILITIES
ALTERNATIVES EVALUATION AND PREDESIGN PROJECT
RECOMMENDED BOARD ACTION:
1. Authorize the General Manager to execute a Professional Engineering Services
Agreement with Black & Veatch Corporation up to $2,000,000 for the Solids
Handling Facilities Alternatives Evaluation and Predesign Project.
2. Authorize the General Manager to transfer up to $2,000,000 in the Capital
Improvement Budget (GIB) from existing District Projects being consolidated to
form the Project.
Page 10 of 10