HomeMy WebLinkAbout03.d. Review draft Position Paper to authorize the General Manager to include final design services in the existing professional engineering services agreement with Black and Veatch Corporation for the Solids Handling Facility Improvements - Ph1, DP 7348Item 3.d.
CENTRAL SAN BOARD OF DI RECTORS
POSIT ION PA PER
DRAFT
M E E T ING D AT E:MA R C H 13, 2018
S UB J E C T: R E V I E W D R A F T P O S I T I O N PA P E R TO A UT HO R I Z E T HE G E NE R A L
MA NA G E R TO I NC L UD E F I NA L D E S I G N S E RV I C E S I N T HE E X I S T I NG
P R O F E S S I O NA L E NG I NE E R I NG S E RV I C E S A G R E E ME NT W I T H B L A C K &
V E AT C H C O R P O R AT I O N F O R T HE S O L I D S HA ND L I NG FA C I L I T Y
I MP R O V E ME NT S - P HA S E 1, D I S T R I C T P R O J E C T 7348, AT A N
A D D I T I O NA L C O S T NO T TO E X C E E D $5.9 MI L L I O N
S UB M I T T E D B Y:
NAT HA N HO D G E S , A S S O C I AT E E NG I NE E R
I NI T I AT I NG D E PART M E NT:
E NG I NE E R I NG A ND T E C HNI C A L S E RV I C E S-
C A P I TA L P R O J E C T S
RE V IE WE D B Y:C R A I G MI Z UTA NI , S E NI O R E NG I NE E R
E D G A R J . L O P E Z , C A P I TA L P R O J E C T S D I V I S I O N MA NA G E R
J E A N-MA R C P E T I T, D I R E C TO R O F E NG I NE E R I NG A ND T E C HNI C A L
S E RV I C E S
IS S UE
Board of Directors' (Board) authorization is required f or the General Manager to execute an amendment to
a prof essional engineering services agreement for amounts greater than 15-percent of the original
agreement amount.
B AC K G RO UND
On December 1, 2016, the Board authorized the General Manager to execute an agreement with Black &
Veatch Corporation (B&V) for the predesign of the Solids Handling Facility Improvements – Phase 1, District
Project 7348 (Solids Ph. 1) at a cost of $2.0 million. At that time, there were six individual solids process projects
in the Capital Improvement Budget (CIB). Due to the inter-dependency of each project element, it became
apparent that these efforts should be combined into a single project. Decisions made regarding one process
would affect the other processes. T herefore, these projects were combined to create the Solids Ph. 1 project.
Additionally, the Comprehensive Wastewater Master Plan (C WM P) identified several needs such as piloting
wet scrubber and air pollution control equipment, aging infrastructure, and future regulatory requirements. B&V
was hired to take a comprehensive look at Central San’s solids facilities and develop a recommended design
approach for the Solids Ph. 1 to address capacity, reliability, and future regulatory requirements related to each
system for the next 20 plus years.
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T he Solids Ph. 1 predesign consisted of numerous field investigations, workshops, meetings (with Operations,
Maintenance, Planning, and Capital Projects staff), facility tours, piloting, testing, 3-D scanning, and other
important efforts to comprehensively evaluate and recommend improvements. Six (6) technical memorandas
(T M) were produced that recommend improvements to the T M 1: Sludge Blending, T M 2: Sludge Dewatering,
T M 3: Multiple Hearth Furnaces (M H F), T M 4: Seismic Improvements, T M 5: Air Pollution Control, and T M 6:
Ash Handling and Emergency Sludge Loadout Improvements. A seventh technical memorandum (Executive
Summary) was produced to summarize all the recommendations and address global issues, such as impact on
the Federal Requirement Plan for Sewage Sludge Incinerators - Maximum Achievable Control Technology (SS I
MACT ) 50-percent Cost T hreshold, project delivery options, and construction sequencing. Electrical,
instrumentation and controls requirements associated with all the improvements were also included as part of
the T Ms. T hese technical memorandas form the basis for the Solids Ph. 1 final design scope of work.
T he following is a summary of the predesign work and the recommended improvements for final design.
1. Sludge Ble nding and Storage
T he existing sludge blending, and storage system includes the Sludge Blending Tank (S BT ), Emergency
Sludge Storage Tank (E SS T ), and a combination of pumped and mechanical mixing. T he pumped mixing
includes several 75 H P pumps used for mixing. T he S BT was built in 1967 and structurally reinforced in 2015.
T hese tanks were originally constructed as digesters but later converted to their current usage as sludge
storage tanks. T he S BT and E SS T are oversized for day-to-day needs and the mixing system is inadequate
and inefficient. T hese inadequacies result in reduced dewaterability under average and peak loading conditions.
Sludge blending and storage will be improved by installing new, appropriately sized blending tanks to meet the
normal daily operational needs. Additionally, the existing SB T will be converted for use as an emergency tank
and storage during M H F service rotations. T he new blending systems will use smaller 7.5 HP pumps for the
new S BT and 50 H P pumps for the E SS T, which will result in significant energy savings.
2. Sludge Dewatering
T he sludge dewatering consists of four (4) centrifuges and four (4) cake pumps that have been in operation
since 1988 for the centrifuges and 1991 for the cake pumps. T his equipment is at the end of its useful life with
increasing maintenance costs, as demonstrated by the high number of corrective work orders being generated
by our C M M S. Certain centrifuge parts are obsolete and cannot be obtained from the manufacturer or
distributors. New dewatering equipment, combined with improved sludge blending, will provide a consistent
dewatered sludge feed to the M H Fs. Modern Centrifuges are significantly more energy efficient compared to the
existing units and can produce a higher cake with less chemical addition, less energy and a better quality
centrate. Energy savings is also anticipated from reduced auxiliary fuel usage in the M H Fs due to the higher
solids content in the sludge.
3. Multiple Hearth Furnace s
As determined by field investigation and condition assessment conducted during the CWMP, the existing M H Fs
are in overall good condition. Only one M H F is operated at a time, which allows maintenance staff the ability to
routinely inspect and perform repairs as needed on an annual basis. Central San’s past and current
maintenance practices are a key reason why the MHFs continue to perform reliably and are expected to
continue service life for the next 20 or more years.
One of the most significant findings under the Solids Ph. 1 predesign was the confirmation that the M H Fs were
not capacity constrained, and that the MHFs have sufficient capacity up to and beyond the 20-year planning
period. T his conclusion was achieved by actual field-testing performed by staff and verified by B&V.
T he CWMP indicated that the M H Fs would not have enough capacity for the 20-year planning period. T his
resulted in the CWMP recommendation to include two Anaerobic Digesters within the next decade to address
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the lack of solids capacity and for energy resource recovery. Due to work under the Solids Ph. 1 predesign, the
addition of Anaerobic Digesters has been moved to the end of the 20-year planning period.
Two major M H F improvements were recommended as follows:
· Burner Upgrades - T he existing afterburners are significantly oversized and are rarely used.
Installation of appropriately sized afterburners will permit their use for air pollution control and improve
regulatory compliance. Replacement of hearth burners will also improve M H F control. Both after- and
hearth-burners replacement will include new controls, flame supervision, and associated safety
improvements. Energy savings are anticipated.
· Center Shaft Drives - With the recent failure of the hydraulic drive on M H F 1, staff installed an
electric drive with variable frequency drives (VF D). Also, some critical parts from the hydraulic drive are
no longer available. A new electric drive will be installed on MHF 2. T he new center shaft drive systems
will provide reliable control of shaft speed. T his upgrade was also noted on staff’s tour of other facilities
with similar MHF and pollution control equipment. MHFs of our vintage were converted to electric drives
with the failure of hydraulic drive systems and the improved control and lower maintenance costs.
4. Seismic Improv ements
In 2009, a seismic evaluation was performed on the Solids Conditioning Building (S C B). Soon after that time,
the S C B seismic improvements were prioritized behind the Headquarters Office Building (HO B) and the Pump
and Blower Building (P BB) seismic improvements. T he SCB seismic evaluation is based on the same criteria
as the recent H OB and PB B Seismic Upgrade projects. To achieve the same design level, the SCB seismic
upgrade includes column and beam strengthening, infill of an open bay, and installation of a combination of steel
braces and concrete shear walls. Staff is recommending the seismic improvements in coordination with the
Solids Ph. 1 project since this work will impact many of the systems discussed by coordinating equipment
placement, electrical, wall penetrations, clearances, and overall construction sequencing.
T he MHFs are especially vulnerable to a seismic event. T he MHFs are comprised of a thin, outer steel shell,
supporting brick walls (unreinforced masonry refractory), and cast-iron center shaft. Extensive analysis was
conducted during the predesign and determined that base isolators were the best retrofit feasible (technically
and economically) approach for Central San. T hese improvements will isolate the MHFs from the solids building
structure allowing the M H Fs to move independent of the building.
5. Wet Scrubbe r and Air Pollution Control
T he regulatory issues facing the existing wet scrubber equipment include the inability to treat bypass emissions,
difficulties handling a wider range of operational conditions, and consistent compliance with the Clean Air Act
Section 129 (Section 129) hydrogen chloride (HCl) emissions limit, the proposed amendments to Bay Area Air
Quality Management District (BAAQ M D) Rule 6-1 for more stringent particulate matter limits, and BAAQ M D
Rule 11-18 for reduction of risk from air toxic emissions.
Staff and B&V recently completed an extensive pilot test of one possible air pollution control equipment
(Envirocare Wet Scrubber) to accurately estimate performance against current and potential future air emission
limits. T he pilot testing also allowed for measurement of the liquid waste stream to determine if additional
treatment would be required. T he results of pilot testing will be used to select the appropriate equipment and
estimate the project costs associated with air pollution control during final design. T he piloting confirmed that
installation of a multi-Venturi wet scrubber would be sufficient to comply with Section 129 limits for existing
MHFs, Title V permit, and proposed limit for particulate matter (Rule 6-1). Compliance was demonstrated during
the pilot for both normal operation and bypass conditions. Our current system does not allow scrubbing of
bypass conditions. Pilot testing also demonstrated that additional or future air pollution control equipment such
as a Wet Electrostatic Precipitator or mercury modules are not expected to be required at this time. T he results
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of the pilot work are estimated to save $13 million in equipment/infrastructure improvements, almost $100,000
annual savings in operations and maintenance (O&M) costs for systems that may have been recommended
without the pilot.
T he installation of a new wet scrubber is expected to ensure compliance with existing Section 129 and Title V
emission limits for existing M H Fs. Compliance is also expected with respect to particulate matter and health risk
threshold limits (along with furnace burner improvements). Particulate matter limits have been proposed by
B AAQMD and new wet scrubbers are expected to comply with those limits. Health risk assessment limits are
still under development, and staff continues to monitor anticipated regulations and assess impacts for
compliance. T he new wet scrubber will also be designed to treating the bypass emissions, which will educe the
frequency of reportable compliance activity (R C A) due to bypass events which have been experienced lately.
Additional air pollution control technology was evaluated against existing MHF emission limits, new MHF
emission limits, and the more stringent emission limits associated with new fluidized bed incinerators (FB I).
Equipment was recommended in the event Central San must comply with enhanced air emission limits. Building
floor space will be reserved for any future pollution control equipment that may be required. B&V and staff's
understanding of current and near-term future regulations is that the installation of a new Venturi wet scrubber
and furnace improvements is recommended for reliability and regulatory compliance.
6. Ash Handling Facility
T he existing ash system, while well maintained, has many components nearing the end of its useful life and will
need major renovation within the next five years. T his system has experienced difficulties in containing ash
within the SCB and outside the building. T here are also new air emission regulatory drivers such as Section
129 to control visible fugitive ash emissions. A new wet ash system is recommended to replace the existing, dry
ash system. Wet ash systems require less equipment and have lower overall O&M costs. However, a wet ash
system will require some operational changes such as the use of lagoons or a filter system to dewater the ash. A
wet ash pilot is recommended to confirm it will function appropriately and will be compatible with our current ash
disposal requirements prior to final design.
7. Eme rgency Sludge Loadout Facility
T he Emergency Sludge Loadout Facility has deficiencies that prevent it from meeting its performance
objectives. All three silos are connected to the cross conveyor and gates are only located beneath the conveyor
at each of the three discharge chutes. T he existing discharge slide gates are also difficult to control.
Improvements include adding silo isolation gates, improving the discharge gates for better modulation of sludge
flow, and improving drainage. Odor control improvements may also be recommended, until field verified and
tested by staff prior to start of final design.
8. Othe r Project Considerations
Several project considerations were evaluated by B&V due to their impact to the Solids Ph. 1 project as follows:
· Electrical and Instrumentation Coordination and Replacement - T he existing electrical and
instrumentation systems associated with the Solids Ph. 1 have been in service for over 40 years.
Replacement of these systems will be required when new equipment and systems are installed. T he
existing control and electrical room equipment should be replaced to meet current electrical code and to
allow installation of the new equipment while keeping existing facilities operational and online. B&V will
integrate the location of the new electrical and control facilities with the mechanical, structural, and
seismic work in the SCB.
· S SI MACT 50-Percent Cost T hreshold - One of the most important considerations was the SS I
M AC T 50-percent Cost T hreshold. Section 129 mandates that should improvements to an existing
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incinerator exceed 50-percent of the original cost of installation (in present dollars) the incinerator would
be subject to enhanced emission limits. If the cost threshold were exceeded, the MHFs might not be
permitted to operate, or would need additional enhanced air pollution control equipment to be installed in
order to comply with enhanced emission limits.
B&V updated the M H F original installation cost to 2017 dollars. After deducting previous non-exempt
modifications, there is $34.6 million remaining before the 50-percent threshold is exceeded. T he
recommended improvements that would apply against the 50-percent threshold are the cake pumps,
furnace improvements (burner replacement, combustion air blower, and burner controls), and ash
handling. New afterburners may or may not be exempt. T he afterburners would be for air emission
control, and that use is specifically exempt from the 50-percent threshold.
If the afterburners are exempt costs, Central San has approximately $10.2 million remaining in
modifications before exceeding the 50-percent threshold. Because of the comprehensive approach of this
project, with the intent to provide reliable solids handling for the next 20 years, there are no additional
major furnace modifications planned once this project is completed. Potential future work that may count
against the available modification dollar threshold are hearth replacements, and these costs are well
within the $10.2 million range. T he most likely future furnace related improvements would be installation
of additional air emissions control equipment. However, this equipment is specifically exempt from the 50-
percent cost threshold.
· Project Delivery - Delivery options were evaluated. A traditional design-bid-build approach was
selected as the most favorable project delivery method.
Pre-procurement or the centrifuges, cake pumps, and wet scrubbers was evaluated and recommended
for the Solids Ph. 1 project. T here are substantial differences in design and configuration between
potential suppliers of this equipment that selecting the equipment manufacturer during design would
greatly simplify the required work and reduce potential construction complications. T his will have design
savings and reduce the risk of construction change orders and other contractual issues that may arise.
Staff and B&V have already started the pre-procurement process. Equipment suppliers are being
contacted to obtain product and performance data. Staff, B&V, and Central San's legal counsel have also
started to develop the documents for equipment qualifications, selection process, and terms and
conditions. T he total estimated pre-purchase costs of this equipment is $5.1 million.
· Project Sequencing - A project of this magnitude will greatly impact plant operations. B&V has
considered the time required to construct the various project elements. With one MHF off-line at a time,
equipment can be installed, and improvements made near the off-line MHF, with minor risk to solids
treatment. Certainly, not all risk will be eliminated. B&V and staff are developing sequence specifications
that will help minimize operational risk while producing a project that can be ultimately constructed
effectively. B&V will undergo a constructability review of the Solids Ph. 1 project and staff will also seek
input from a third-party P EE R review during the final design process.
· Health Risk Assessment - B AAQMD issued a draft air toxics regulation, Regulation 11, Rule 18
(Rule 11-18) in late 2016. T his rule will require facilities found to pose a significant health risk to reduce
the impacts and control toxic air emissions. B&V’s predesign scope of work included support for Central
San’s internal assessment of what impacts compliance with Rule 11-18 would have on treatment
processes. A preliminary health risk assessment completed by B&V showed Central San will be required
to mitigate health risks from toxic air contaminants in order to comply with Rule 11-18. In late 2017, Rule
18 was adopted. B&V is currently updating the baseline health risk assessment using recently completed
air emissions testing data that will show more accurately which processes contribute to the risk. Included
in B&V’s final design scope of work is assessment on risk reduction strategies. Risk reduction measures
may range from wet scrubber replacement to minor modifications, such as operational changes and stack
modifications. T hese mitigation measures need to be confirmed with B&V’s health risk model in order to
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assess any impact to plant processes and, specifically, to solids process equipment.
Consultant Selection
On October 20, 2017, staff issued a Request for Proposal (R F P) for final design services to the engineering
consulting community via PlanetBids and Central San’s website. B&V was the only consultant to respond to the
RFP. Staff reviewed the proposal and considers B&V capable of meeting Central San's needs to complete the
final design.
CE QA:
At its December 1, 2016 meeting, the Board independently found that the agreement with this vendor was
exempt from the California Environmental Quality Act (CE QA) under Central San’s C EQ A Guidelines Section
15262, since it allowed for further planning and feasibility studies for possible future actions which Central San
has not approved, adopted, or funded, and the outcome of these tasks will not have a legally binding effect on
later activities. Central San will conduct an environmental evaluation of any capital project that is proposed in
the future as a result the tasks authorized herein to determine the need for any additional CE QA documentation.
ALT E RNAT I V E S /C O NS I D E RAT IO NS
An alternative would be to phase or postpone the construction improvements, which is not recommended due to
the solids process dependency and design complications previously noted above.
A new wet scrubber and air pollution control improvements would significantly help the current issues being
experienced with bypass events and reduce chemical costs in controlling HCI emissions.
Although the proposed CIB and current budget have adequate cash funding for the final design, it is anticipated
that Central San will most likely request bond financing to construct these improvements. T his decision will be
presented at a future Board Meeting and no action is required at this time.
F I NANC IAL I M PAC T S
T he B&V final design services for the Solids Ph. 1 project is estimated at $5.9 million. T he total B&V agreement
cost ceiling is estimated at $8.1 million ($2.0 million for pre-design and piloting assistance, $230,000 for the
design of the urgent water system upgrades, and $5.9 million for final design), which is approximately 10-percent
of the $82 million total estimated project cost as detailed in Attachment 1.
T he Solids Ph. 1 project is listed in the Fiscal Year (F Y) 2017-18 CIB on page 161 with a budget of $2,650,000
this fiscal year and $8,200,000 for F Y 2018-19. T he design costs will span two fiscal years with funding as
shown in the following table:
F inancial Impact Table:Amount
x F unds budgeted this F Y 2017-18 f or this project $2,625,000
o F unds taken from current F Y 2017-18 C I B contingency $ 0
F unds transf erred f rom current F Y 2017-18 projects :
o a. Updated f orecast; estimated savings f rom project available $ 0
x b. A cceleration of funds for project that is budgeted in future year $ 3,275,000
o c. Combined project scope for bidding purposes $ 0
o
d. Potential f uture year budget impact
(May be mitigated through (1) savings f rom close-outs of current
year projects; (2) reprioritizing f uture year projects; (3) cost
savings on future year projects)
$ 0
Total C urrent Year Cost $ 5,900,000
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C O M M I T T E E RE C O M M E ND AT IO N
T he Engineering and Operations Committee reviewed this agreement amendment at the March 13, 2018
meeting and recommended approval to include final design services for the Solids Ph. 1 project.
RE C O M M E ND E D B O ARD AC T I O N
Authorize the General Manager to include final design services with Black & Veatch Corporation, Agreement
044848, in an amount not to exceed $5.9 million for the Solids Handling Facility Improvements Project-Phase 1,
District Project 7348.
Strategic Plan Tie-I n
G O A L TW O: Strive to M eet Regulatory Requirements
Strategy 1 - Strive to Achieve 100% Permit Compliance in Air, Water, Land and Other Regulations
G O A L TH R EE: Be a Fiscally Sound and Effective Water Sector Utility
Strategy 1 - Conduct Long-Range Financial Planning, Strategy 2 - Manage Costs
G O A L FI VE: M aintain a Reliable I nfrastructure
Strategy 1 - Manage Assets Optimally Throughout Their Lifecycle, Strategy 2 - Facilitate Long-term Capital Renewal
and Replacement
G O A L S I X: Embrace Technology, I nnovation and Environmental Sustainability
Strategy 2 - Evaluate Business Processes and Optimize Business Operations
AT TAC HM E NT S :
D escription
1. E stimated C apital C osts of R ecommended I mprovements
2. (Handout) Updated P resentation
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Attachment 1
Solids Handling Facility Improvements - Phase 1
District Project 7348
Estimated Capital Costs of Recommended Improvements
Item Recommended Improvements Total Construction Cost Total Project Cost
1 Sludge Blending and Storage $2,590,000 $3,700,000
2 Sludge Dewatering $11,780,000 $16,500,000
3 Multiple Hearth Furnaces $8,750,000 $12,300,000
4
Seismic Improvements
Building Seismic Retrofit
Furnace Seismic Retrofit
$11,100,000
$3,000,000
$15,600,000
$4,200,000
5 Wet Scrubber and Air Pollution Control $10,560,000 $14,800,000
6 Ash Handling Facility $7,430,000 $10,500,000
7 Emergency Sludge Loadout Facility $3,200,000 $4,500,000
Total Capital Costs $58,410,000 $82,100,000
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SOLIDS HANDLING FACILITY
IMPROVEMENTS
PROFESSIONAL ENGINEERING SERVICES FORSOLIDSHANDLINGFACILITIESPHASE1 FINAL DESIGN
Engineering and Operations Committee Meeting
March 13, 2018
Jean-Marc Petit, Director of Engineering and Technical Services
Edgar Lopez, Capital Projects Division Manager
Nathan Hodges, Associate Engineer
Item 3.d.
(Committee Handout)
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SOLIDS PHASE 1 PROJECT BACKGROUND
•Project Identified in CWMP (and over past 12 years in
CIBs)
•RFP issued for pre-design in 2016
•B&V selected and awarded on December 1, 2016
•Completed Preliminary Design over past 14 months
•RFP issued for final design B&V selected
•Recommending to proceed with Final Design
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Improve efficiency and reliability Maintain regulatory compliance
Increase capacity
Replace Aging
Infrastructure
Reduce water and energy usage
ORIGINAL PROJECT DRIVERS
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Improve efficiency and reliability Maintain regulatory compliance
Increase capacity Reduce water and energy usage
UPDATED PROJECT DRIVERS
Replace Aging
Infrastructure
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PRELIMINARY DESIGN COMPLETED
BY CONSULTANT
•Assisted staff with testing (lime reduction, air pollution control pilot,
capacity testing)
•Performed risk modeling to assess District approach on draft BAAQMD
Rule 11-18 (Adopted November 15, 2017)
•Completed 10% preliminary design on improvements to maintain
existing solids facilities:
•Solids Storage/Blending Facilities
•Dewatering Facilities
•Air Pollution Control Equipment
•Ash Handling
•Seismic Improvements for Solids Building and Furnaces
•Emergency Sludge Loading Facility
•Preparing Specifications and Drawings for Equipment Procurement for:
•Centrifuges
•Dewatering Sludge Pumps
•Air Pollution Control EquipmentMarch 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 46 of 87
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UPDATED FLEXIBLE PHASED APPROACH TO SOLIDS HANDLING WITH
PHASE 1 SOLIDS IMPROVEMENT PROJECT
MHFs
Design Phase 1 Solids
Handling Facilities
Improvement Project
Phase 2
(6-10 yrs.)
Yes
Phase 4
(> 20 yrs.)
Phase 1
(0-5 Years)
COGEN
Implement
Cogen
Improvement
Project
Innovative BioEnergy
New Alternative Solids
and Energy Technology
Project Evaluation (e.g.;
Gasification)?
Yes
Yes
MHFs
Construct Phase 1
Solids Handling
Facilities
Improvement Project
Innovative BioEnergy
Construct and Operate Phase 1 BioEnergy Project:
Demonstration Phase: 10 yrs.
COGEN
Renew 5 Year Solar
Turbine Maintenance
Agreement
Yes MHFs
Construct Phase 2/3 Solids
Handling Facilities
Improvement Project
Yes
COGEN
Replace COGEN
with a 5-Year Mfr.
Maintenance
Agreement
Innovative BioEnergy
Construct Phase 2 BioEnergy Project
Full Scale 20 years
Phase 3
(11-20 yrs.)
No
COGEN
Renew 5 Year Solar Turbine Maintenance Agreement
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 47 of 87
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OVERALL PROJECT OBJECTIVES
•Ensure reliable capacity and operation of the
MHFs and related systems over next 20+
years
•Reduce MHF emissions and ensure reliable
emissions and permit compliance
•Reduce, minimize, and eliminate majority of
reportable Bypass Events
•Accommodate future air pollution control
should SSI MACT 50% cost be reached
•Improve overall solids handling reliability and
performance; reduce water/energy usage
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 48 of 87
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SOLIDS IMPROVEMENT, PHASE 1
PROJECT SCOPE
Centrifuge and Cake Pumps Replacement
New Air Quality Control Equipment
Emergency Sludge Storage Tank
Emergency Loadout Improvements
Seismic Design (SCB and MHFs)
Electrical and Controls Upgrade and Replacement
AshLoadout Improvements
Furnace Burner Controls Improvements
New Sludge Blending Tank with Mixing
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INTEGRATED PILOT TESTING WILL MINIMIZE FUTURECOSTSANDPLANTOPERATIONIMPACTS
Lime Bench-
Scale Testing Centrifuge Testing Centrifuge
Upgrade
Centrate Test
LIME/
CENTRIFUGEIntegrated Pilot
Tests Completed
during Pre-
Design
CFD
Modeling
Mixing
Upgrades
Sludge
Blending
Tank
Desktop MHF Capacity
Evaluation
Full Scale MHF Test on
Reduced Lime Sludge
MHF Capacity
Test Furnaces
MHF
Install Pilot
Equipment AIR EMISSION
Duct Connections
Procurement
Air Permitting
Scrubber Pilot
Air Emissions Test
Scrubber Effluent Test
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 50 of 87
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SOLIDS HANDLING PROJECT
REGULATORY DRIVERS
•A new scrubber will help ensure compliance with existing and
near-term incinerator regulations:
Clean Air Act Section 129 Regulated Use of Emergency Bypass
Damper
Clean Air Act Section 129 HCl Emissions Limit
Proposed Amendments to Bay Area Air Quality Management
District Particulate Matter (PM) Rule 6-1
More stringent PM concentration limit
Recently Adopted BAAQMD Rule 11-18, Air Toxics Reduction
Health risk assessment requirement
If treatment plant cancer risk is >10/M or non-cancer index >1,
risk reduction measures will be needed to reduce below trigger
levels
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HRA EVALUATED PRELIMINARY ALTERNATIVES FOR
TOXICS REDUCTION FROM MAJOR CONTRIBUTORS
TO AVOID RISK ACTION LEVEL TRIGGERS
Emissions Source Potential Toxic Air
Contaminant Mitigation
Measures
Contaminants Reduced
Incinerators Wet scrubber
Wet ESP
Afterburner
Metals
Toxic Organics
Auxiliary Boilers Extend Stack Height
Activated Carbon
Metals
Toxic Organics
Preliminary Treatment
Headworks and Bar Screens
Contain & Treat
(Odor Control Scrubber and
cover on open areas)
Completed
H2S
Toxic Organics
Primary Treatment Cover & Treat
(Bioscrubber, Biofilter,
Carbon)
Toxic Organics
Secondary Treatment Cover & Treat
(Biofilter, Carbon)
Toxic Organics
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 52 of 87
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New Wet
Scrubber
System
Potential
Future
Enhanced
Air
Pollution
Controls
New Sludge Cake
Pump System
New
Dewatering
Centrifuge
System
New Afterburner
System
SSI MACT 50% COST RULE TRIGGERS
EXEMPT
LIKELY EXEMPT
NON-EXEMPT
MHF and
Building Seismic
Upgrades
Centershaft Drive
Replacement (w/ VFD)
Potential Future
Refractory Work
Potential Future
WHB Upgrades
Ash Handling
and Loadout
Improvements
Emergency Sludge
Loadout
Improvements
Combustion Air Blower
Replacement
Burner & Control
Upgrades
New
ID Fan
New Sludge
Blending,
Polymer,
and Lime
Systems
MACT (Maximum Achievable Control Technology
New Emergency
Bypass
Potential
Future Wet
Scrubber Side
Stream
Treatment
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 53 of 87
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RECOMMENDED IMPROVEMENTS FROM PRE-DESIGN
EFFORT
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SLUDGE BLENDING IMPROVEMENTS1
•New Lime System
•New right-sized lime silos and metering pumps
•Repurposed Sludge Blending Tank
•Convert current sludge blending tank to emergency sludge storage tank w/ engineered pump mixing system
•New Sludge Blending Tanks
•New sludge blending tanks sized for improved mixing of primary sludge and TWAS w/ vertical turbine mixing system
•Next Steps
•Evaluate and conduct full scale lime reduction test to optimize lime addition
•Design Recommended Improvements
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SLUDGE DEWATERING IMPROVEMENTS2
•New Polymer System
•New polymer storage tanks, day tank, transfer pumps, blending units, and feed tanks to serve new dewatering centrifuges
•New Dewatering Centrifuges
•Four new high efficiency centrifuges to replace centrifuges beyond useful life
•New Sludge Cake Pumps
•Four new cake pumps w/ flow metering to replace pumps beyond useful life
•Next Steps
•Prepare documents for procurement of dewatering centrifuges and cake pumps
•Final designed based on selected equipment
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 56 of 87
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FURNACE IMPROVEMENTS3
•New Burners and Controls
•New low-NOx afterburners on hearth 1 for CO/NOx emissions reduction and new low-NOx burners on hearths 2 –10; new modern, automated controls on all burners
•New Center Shaft Drive System
•New center shaft drive system w/ VFD to replace unreliable hydraulic drive system
•New Combustion Air Blower System
•New combustion air blower to be integrated w/ new burner control system
•Next Steps
•Coordinate design and implementation of furnace improvements w/ seismic retrofit
•Complete Final Design
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 57 of 87
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USE OF 3D CAD DESIGN WILL BE USED TOIMPROVECOLLABORATIONWITHO&M STAFF
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 58 of 87
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3D DESIGN IMPROVES COLLABORATION AND
DESIGN ACCURACY
•Facilitates District review of preliminary
design alternatives
•Cake conveyance/storage concept
to improve operational flexibility
•Drives high quality design
•Interference detection and
observation
•“Walk through” for District review of
operations access and maintenance
space and hoisting provisions
•Leverage 3D model to develop
construction phasing and help maintain
plant operations
•Facilitates cost estimating
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•Confirm Target Seismic
Performance levels for building
and MHFs
•Update building seismic
evaluation for the following:
•Target Seismic Performance
Level
•ASCE 41-13 Seismic
Evaluation & Upgrade
Standard
•New short term and long term
SCB equipment modifications
•Update and further develop base
isolation concepts for MHFs Solids Conditioning Building
IMPROVING RELIABILITY WITH SEISMICUPGRADES
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 60 of 87
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SLUDGE CONDITIONING BUILDINGDESCRIPTION
SOLIDS CONDITIONING BUILDING
•Constructed in mid-1970s
with partial seismic upgrade
in 1985
•126 feet by 180 feet –4
levels
•Gravity System –Concrete
slab spanning to steel beams
and columns
•Lateral System –Concrete
diaphragm with large
openings, steel moment
frame and stair towers
Northwest Corner of Solids
Conditioning Building
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 61 of 87
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MULTIPLE HEARTH FURNACEDESCRIPTION
FURNACE
•Constructed in 1974
•22 feet in diameter, 60 feet
tall
•Constructed of
unreinforced brick
•Encased in a thin steel
plate shell
•Rotating cast iron inner
shaft
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 62 of 87
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SEISMIC ANALYSIS RESULTS
1. SOLIDS CONDITIONING BUILDING SEISMIC DEFICIENCIES
•Concrete shear walls at stair towers are overstressed in shear
•Columns and beams are overstressed
•Diaphragm capacity is inadequate to transfer forces
•Moment frames and connections are inadequate
•Braces have inadequate connection capacity
2. FURNACE DEFICIENCIES
•Cast iron center shaft is brittle and overstressed in flexure
•Brick hearths could collapse in DBE
•Unreinforced brick along perimeter inadequate in shear and
flexure
•Steel shell could buckle in DBE
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 63 of 87
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MODELS
SOLIDS CONDITIONING BUILDING :
ETABS 2015 Model Wall Shear Stresses
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 64 of 87
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SEISMIC UPGRADE CONCEPTS
•Add new concrete shear
walls
•Strengthen select
columns and beams
•Add horizontal
diaphragm braces
•Infill slab on first floor
•Strengthen existing
brace connections
•Isolate stair towers from
building
SOLIDS CONDITIONING BUILDING:
STRENGHTHENING SCHEME
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 65 of 87
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SEISMIC UPGRADE CONCEPTS FORFURNACES
•Add new base isolators under each column
and center shaft
•Add braces at furnace base columns and
center shaft
FURNACE STRENGHTHENING SCHEME
•Add seismic joints for all
utility connections,
stairs and platforms
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 66 of 87
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SEISMIC UPGRADE CONCEPTS
Example: Friction Pendulum
at Kealakaha Bridge
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 67 of 87
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SEISMIC UPGRADE CONCEPTS FOR MHFS
Existing Furnace Base
Conditions
Base Condition with Isolators
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 68 of 87
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SEISMIC IMPROVEMENTS RECOMMENDATIONS4
•Separate Stairwells and Elevators
•Seismically separate stairs and elevator core walls from building
•Add Shear Walls and Infill Slabs
•Strategically locate new shear walls and infill slabs to seismically strengthen building
•Isolate Furnaces from Building
•Install new MHF base isolators and flexible duct, piping, and conduit connections to allow for lateral movement of furnaces
•Next Steps
•Design and implementation of seismic improvements for the SCB and MHFs
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 69 of 87
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AIR POLLUTION CONTROLIMPROVEMENTS5
•New Wet Scrubbers
•New high performance wet scrubbers to replace wet scrubbers beyond useful life
•New MHF Emergency Bypass
•Route dry scrubber/waste heat boiler bypass to new wet scrubbers for treatment
•New Ash Slurry Drain System
•Route wet scrubber drain to new wet ash handling system with potential future treatment to reduce metals
•Next Steps
•Prepare documents for procurement of
wet scrubbers
•Include elements in design layout for
potential additional modules that may be
required by future regulations
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 70 of 87
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ASH HANDLING AND LOADOUT SYSTEMIMPROVEMENTS
6
•New Wet Ash Loadout System
•Replace dry ash loadout system with wet ash loadout system w/ ash dewatering in truck trailer or loadout container
•New Wet Ash Collection System
•Replace MHF dry ash conveyor w/ new wet ash receivers and drain from wet scrubbers
•New Ash Slurry Pump System
•Replace dry ash vacuum system w/ new ash slurry pumps and piping
•Next Steps
•Conduct wet ash loadout system bench
scale and pilot testing to verify
performance
•Finalize design of new ash loading system
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 71 of 87
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Dewatered
Cake
Storage
IMPROVE EMERGENCY SLUDGE LOADOUTFACILITY
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EMERGENCY SLUDGE LOADOUTIMPROVEMENTS
6
•New Sludge Loadout Operation
•Add sludge discharge gates to allow even filling of trailer without moving truck
•New Sludge Loadout Odor Control
•Expand odor control system to capture vents from new sludge loadout chutes
•New Sludge Loadout Containment
•Upsize sludge loadout drainage system and add retractable curtain containment around sludge loadout truck
•Next Steps
•Design improvements to emergency
sludge loading building
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 73 of 87
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ELECTRICAL AND CONTROLSIMPROVEMENTS7
•New PLC Control panels for all new equipment
•Provide new local control panels with PLC for all new process equipment and connect with SCADA system
•New MCCs for Equipment in SCB
•New MCC Room
•New Furnace Controls
•Replace obsolete hard wire control panel
•Next Steps
•Engineer site visits to inventory
electrical and control equipment
•Design improvements to emergency
sludge loading building
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 74 of 87
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ESTIMATED CAPITAL COSTS OFRECOMMENDEDIMPROVEMENTS
1
2
3
4
5
6
RECOMMENDED IMPROVEMENTS TOTAL
CONSTRUCTION COST
TOTAL
PROJECT COST
Sludge Blending and Storage $2,590,000 $3,700,000
Dewatering System $11,780,000 $16,500,000
Furnace $8,750,000 $12,300,000
Building Seismic Retrofit $11,100,000 $15,600,000
Furnace Seismic Retrofit $3,000,000 $4,200,000
Air Pollution Control $10,560,000 $14,800,000
Ash Handling and Loadout System $7,430,000 $10,500,000
Emergency Sludge Loadout Facility $3,200,000 $4,500,000
TOTAL CAPITAL COSTS $58,410,000 $82,100,000
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 75 of 87
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Project cost Estimates
Total Project Cost Estimate, $M
Project Elements Original DP No.FY 2016 Proj No.FY 2018
Wet Scrubber Replacement In CIB (TBD)$ 30.00 7348 $ 14.80
Wet Scrubber Pilot, Other 7315 $ 0.85 7348 $ 1.10 **
Dewatering System 7286 $ 12.40 7348 $ 16.50
Sludge Blending In CIP $ 2.90 7348 $ 3.70
HRA New Rule $ 0.20 7348 $ 0.30
Lime Reduction 7315 $ 0.15 7348 $ 0.02 **
Ash System 7312 $ 2.00 7348 $ 10.50
SCB Seismic In CIP $ 13.50 7348 $ 15.60
MHF Seismic In CIP $ 5.00 7348 $ 4.20
Total Project Cost $ 67.00 $ 66.72
Added and Changed Scope
Emergency Sludge Loadout In CIP $ -7348 $ 4.50
MHF (burners)7329 $ 0.85 7348 $ 12.30
Revised Total Project Cost $ 67.85 $ 83.52
Note: This includes E/I&C $ 0.70
** Not included in BV's $82.1M cost estimate
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 76 of 87
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PROJECT SCHEDULE
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2018 2019 2020 2021 2022
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
Equipment Procurement
RFP and Equipment Selection
Equipment Procurement
Shop Drawings and Fabrication
Final Design
(30%, 60%, 95%, 100%)
Bidding
Bid and Award
Construction
Installation and Commissioning
ANTICIPATED DESIGN ANDCONSTRUCTIONSCHEDULE
Procurement Phase: January 2018 –August 2019
Design Phase: April 2018 –October 2019
Bid & Construction Phase: October 2019 –December 2022
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 78 of 87
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ANTICIPATED CASH FLOW FOR
PROJECT
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 79 of 87
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NEXT STEPS AND
RECOMMENDATIONS
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 80 of 87
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NEXT STEPS
•Prepare equipment procurement documents: Jan –May 2018
•Conduct lime and wet ash performance tests: May –Sept 2018
•Finalize Design of Phase 1 Solids Handling Facility Improvements Project: Apr 2018 –Oct 2019
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 81 of 87
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STAFF RECOMMENDATIONS
•Authorize the General Manager to include final design
services in Agreement Number 044848 with Black &
Veatch Corporation in an amount not to exceed $5.9
million for the Solids Handing Facility Improvements
Project-Phase 1, District Project 7348
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QUESTIONS?
March 13, 2018 EOPS Regular Committee Meeting Agenda Packet - Page 83 of 87
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