HomeMy WebLinkAbout03.c. Introduction to the Energy Recovery and Blower Replacement Project Page 1 of 17
Item 3.c.
Central Contra Costa Sanitary District
May 7, 2018
TO: ENGINEERING AND OPERATIONS COMMITTEE
FROM: NITIN GOEL, ASSOCIATE ENGINEER
NANCY MOLINA, ASSOCIATE ENGINEER
REVIEWED BY: DAN FROST, SENIOR ENGINEER
DANEA GEMMELL, PLANNING AND DEVELOPMENT SERVICES DIVISION
MANAGER
EDGAR LOPEZ, CAPITAL PROJECTS DIVISION MANAGER
JEAN-MARC PETIT, DIRECTOR ENGINEERINGAND TECHNICAL
SERVICES
SUBJECT: INTRODUCTION TO THE ENERGY RECOVERYAND BLOWER
REPLACEMENT PROJECT
The 2017 Comprehensive Wastewater Master Plan (CWMP) evaluated the existing energy and aeration
systems and secondary process and recommended replacement and upgrades to these facilities based
on their aging condition and opportunity for improved reliability, flexibility, and optimization. Central San's
existing energy and aeration systems and secondary process are maintained well and have performed
reliably for many years. However, many of these facilities originally installed in the late 1970s and early
1980s are based on outdated and less efficient technology, require ongoing maintenance attention, are
very complicated, complex, expensive to maintain, and have operational limitations such as limited
turndown capabilities and redundancy. As facilities become less reliable and require frequent repairs and
replacement, there is an opportunity to determine whether or not Central San should continue to replace
equipment in kind (i.e. continue with the existing steam-based energy recovery system) or to consider
other options.
As Central San prepares for replacement of these critical facilities, it's important that alternatives are
flexible and optimal for addressing potential future permit requirements for nutrient removal and support
collaborative efforts to expand the use of recycled water such as the Water Exchange concept.
The Energy Recovery and Blower Replacement Project Pre-Design will assess the condition and
remaining useful life of the existing boiler feedwater, steam, and aeration systems, and associated
structural, electrical and instrumentation/control systems; confirm the best energy recovery and aeration
system replacement alternative that addresses both current and future needs; prepare business case
evaluations and prepare 10 percent level design documents, including updated project cost,
phasing, prioritization, and sequencing.
Staff will present the attached PowerPoint presentation that summarizes the importance and approach for
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the Energy Recovery and Blower Replacement Pre-Design.
Strategic Plan re-In
GOAL TWO: Strive to Meet Regulatory Requirements
Strategy 1 - Strive to Achieve 100% Permit Compliance in Air, Water, Land and Other Regulations
GOAL THREE: Be a Fiscally Sound and Effective Water Sector Utility
Strategy 1 - Conduct Long-Range Financial Planning, Strategy 2- Manage Costs
GOAL FIVE: Maintain a Reliable Infrastructure
Strategy 1 - Manage Assets Optimally Throughout Their Lifecycle, Strategy 2- Facilitate Long-term Capital Renewal
and Replacement
GOAL SIX: Embrace Technology, Innovation and Environmental Sustainability
Strategy 1 -Augment the Region's Water Supply, Strategy 2- Evaluate Business Processes and Optimize Business
Operations, Strategy 3- Encourage the Review and Testing of Promising and Leading Technology, Strategy 4- Reduce
Reliance on Non-Renewable Energy
ATTACHMENTS:
1. Presentation (Replaced by revised version)
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Item 3.c.
(Handout)
k
INTRODUCTION TO THE
ENERGY RECOVERY &
BLOWER REPLACEMENT PROJECT
DP 7349
_ Jean-Marc Petit
Director of Engineering & Technical Services
Engineering & Operations Committee
May 7, 2018
1
DRIVERS FOR STARTING PRE-DESIGN
OF ENERGY AND BLOWER
REPLACEMENT PROJECT
Condition
RedundancyAssessments/ Replace Aging/ Equipment
Remaining Unreliable Assets
Useful Life
Improve Energy Optimization/ Prepare for
Efficiency/ Performance/
Sustainability Water Quality Nutrient
Removal1
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THERE IS AN INTER-RELATIONSHIP
BETWEEN THREE PROJECTS
IM
Energy Recovery
& Blower
Replacement
Water Nutrient
Exchange Removal
WATER EXCHANGE PROJECT
HAS MANY BENEFITS
7 r Regional
Maximize Collaboration
Resource Recovery (Central San,
CCWD, SCVWD)
Reduced Sustainable
Nutrient Loads to Future
Suisun Bay
2
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71
.. ���� IO��aw 3 ion��Ilft
•��� --
y
17
JjEnergy Recovery and Blower Replacement Project
1 i ,
,. Steam Generation
w New
Blower Boiler Feed Water
Building? I Steam&
Condensate
e. - Piping
Is
*'TAV
fit
v I
C _ _
Optimize Selector. New Diffusers&Piping
& Dedicated
Aeration Tank Rehab
+ � ��✓ _ ,.��-, I I• Aerated Grit
VVV
RBlowerse-Use Blower Building _ _ _a
for New Blowers? r—
SUB 52 Electrical Upgrades
3
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0 Secondary Treatment/Electrical Considerations
Electrical Upgrades � '��'
6 , \
Mixed Liquor yy
H draulic C
Y �w
Splitter Box
Rehab Clarifiers —J
SUB 33&34 � ��. Add
Electrical Upgrades Generator
t unl�lau! �
0 Planning for Water Exchange
SUB 82
Electrical Upgrades
1 �`
20 MGD Water Exchange:
BNR/MBR or Nereda°GAS
+Microfiltration+Blended Reverse Osmosis
Cb
f
11 +�
11� .[jai
Divert 20 MGD Conventional Activated Sludge
4
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0 Planning for Future Nutrient Removal Level 1
SUB 82
Electrical Upgrades
I` - -- y'+mss.
e - New
f Blower `r �
■ Building
a
CEPT
Cb
� I
Seasonal Nutrient
Optimize Selector Removal:New ,,
Diffusers&Piping&
Aeration Tank Rehab r'i•' ', I�, '
Re-Use Blower Building r •�
for New Blowers? SUB 52 Electrical Upgrades
ir
0 Planning for Future Nutrient Removal Level 2
SUB 82 Contaminated Soil
Electrical Upgrades Future Nutrient Relocation
Future Clarifiers Removal BNR Tank
New
Blower
m ❑ Building
CEPTCb1I
,
Seasonal Nutrient
Optimize Selector Removal:New Pr
Diffusers&Piping& �■ I �` '
Aeration Tank Rehab
i.
Re-Use Blower Building yY�- �
for New Blowers? SUB 52 Electrical Upgrades
5
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Coordinated Efforts for Secondary Improvements &Water Exchange
SUB 82 x *' Contaminated Soil
Electrical Upgrades Future Nutrient Relocation
Future Clarifiers Removal Tanks Steam Generation
Water Exchange .w y
4 New Boiler Feed Water
Blower
❑ Building Steam&
Condensate
Piping
Mixed Liquor Rehab Clarifiers
Hydraulicw Add
Splitter Box Generator
CEPT Y�
SUB 33&34
Electrical Upgrades �� i t•
New Diffusers&Piping -
Optimize Selector &Aeration Tank Rehab
,� - Dedicated
Y.1
l
Aerated Grit
h ` �+r.qr
Y' Blowers
Re-Use Blower Building
for New Blowers? SUB 52 Electrical Upgrades &
CONSIDERATIONS FOR
THE WATER EXCHANGE PROJECT
ProjectConfirm
QualityEstablishing MOUS Elements W,4 Identify
with CCWD & (e.g.Quantity& MA" Alternatives
SCVWD
Outreach, N the Refineries)Proceed with Perform Business
Water Exchange C
Select Best Case Analysis of
(Demonstration the Alternatives
Agreements, etc.)
6
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HOW DOES THE ENERGY RECOVERY &
BLOWER REPLACEMENT PRE-DESIGN FIT IN?
Confirm Identify
Detailed Condition Vcapacities
Assessments Design Criteria (CurreT
(Current&Future Water Exchange
ater Exc range
Prepareir
1
Develop Lifecycle
CostsPreclesign and Select Best •
confirmAlternatives
•
Cost and Phasing urrent&Future
REASONS FOR STARTING ENERGY
RECOVERY & BLOWER REPLACEMENT
PRE-DESIGN
Steam system is complex and aging (need to
be ready for replacement with in kind or
different system)
Maintenance on energy recovery & steam
related systems are significant
Increasing number of reportable compliance
activities (RCAs) on Title V Air Permit related to
energy recovery & steam systems
1
7
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BOILER FEEDWATER &
STEAM SYSTEM
Complex Boiler Feedwater & Return Condensate System
Legend
Water
Hard Steam _ High Pressure
CCWD Return
Water Condensate
+ Chemical
7Exchange
on Feed
Cogen
System
en
Deaerator Waste
Return Deaerator Heat
Condensate Storage
Tank Tank Boilers
Low Pressure Auxiliary
t- Return Boilers
M Condensate
Issues:
1. Integrated System- Complex system: 2 aux. boilers, 1 WHB,and 1 Cogen Boiler
2. Limited Redundancy-It is a challenge with replacing equipment/valves/etc.
3. Unknown life- Boiler feed water system components remaining useful life unknown
4. Operating Pressure -Boiler feed water operating pressure higher than design
8
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BOILER FEED WATER VALVE REPLACEMENT
TRIGGERS MAJOR PLANT COORDINATION IN 2018
➢ Shutdown Aeration Turbines
➢ Transition to Electric Blower t
➢ Shutdown Cogen & WHB
(i.e. import PG&E power) -
k
➢ Shutdown Boilers & Boiler
Feed Water System -
➢ Perform Repairs
➢ Start-up All Systems
)
Steam System is Critical for the Secondary Process
Furnace Exhaust I Dry Wet Induced
Scrubber .7
e,
Scrubber Draft
Fan
Scrubber Water
to Primary
Steam Piping Effluent Steam Pre-Aeration
Turbine
Cake
Multiple Blowers
Hearth
Landfill gas FurnacesIleariat 7S. m
Standby m Plant Heat rs A/N Tanks
Power Boiler
Potable I Feeds: Facility
Water Boiler
Feed MHF Boilers Mixed Liquor
Cogen Boiler Cogan Auxiliary LlChannels
Water Aux.Boilers Electricity Metef b Boilers
from Grid Turbine
Final Effluent
Ash Channel
annel y
Handling
System Natural Gas Q
Future Needs
(Nutrient
Backup Removal&
Electric Water
Blower Exchange)
I
9
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Emergency Existing System After Solids Facilities Improvement Project
Bypass
Stack
Opened? Furnace Exhaust UWaste
ry Heat
Scr�bb
Low Water
Scrubber Water
Level in to"mat,
W." Steam PI Effluent
Ping Steam
Turbine
Cake M1pBlowers
H rt New Bypass Duct.
Hearth
Landfill gasEI_:
Furnaces Waste Steam
'to Plani Heat
Users
Boiler
Potable �Fe
Feeds:
water
MH Boilers Mixed Liquor
Cogen Boiler Co en Auxiliary channels rs
Water
Aux.Boilers Electricity n7eoer g Boilers Q
from Grid 7urbine
Final Effluent
AshChg 4 a""el�
Handling Backup
System Natural Gas Meter Electric
Blower
Issues:
• New Bypass Duct 4 Bypass WHB 4 New wet scrubber system 4
Mitigate most regulatory risks
• However, if continue with steam system, root cause of bypasses
issues may continue to occur
AERATION SYSTEM
ob-
-I
10
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2 STEAM DRIVEN TURBINE BLOWER &
1 ELECTRIC BLOWER
Schematic for Aeration Turbine-Blower System
S _ ROOF
Steam
Relief
In Condensate BLOWER 1
Vacuum 1
1
Coaling Water TURBINE 51219 1
3 H
Y 2W GOVERNOR VALVE (TYPICAL OF 2 ;
TRIP AND THROTTLE VALVE
Control Valve BYPASS VALVE TURBINE AIR INLET tl�
C
p Relief Valve 2W t
Lei Check Valve N TRAPS BYPASS VALVE ;
Manual Valve CONTROL ! 1 1
VALVE GLAND SEAL 1
CONDENSER BYPASS —
P&B BUILDING GROUND LEVEL FLOOR
RELIEFS DISCHARGE SILENCER
STRAINER WEIGHTSII_�
F-7
COO IN
FROM SEPARATOR-PURIFIER 75115 WATER CONDENSER 51104 CONDENSER 2
STEAM
HEADERS 3WHP TO VACUUM
SUB-COOLER
HOT HOGGER PUMP 51113
WELL
CONDENSATE
VIA TRAPS CONDENSATE
TO DEA E RATOR TO 2W VIA SUMP TO
VIA HIGH PRESSURE ATMOSPHERE RETURN TANK
RETURN CONDENSATE IN SCB
SYSTEM 2W COOLER
P&B BUILDING LOWER LEVEL FLOOR VACUUM PUMP 51110 HOTWELL PUMP 51107
11
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ISSUES WITH STEAM & ELECTRIC BLOWERS
Issues:
1. Reliability During Parallel Operation - Existing steam-
driven blowers (65,000 scfm ea.) don't operate reliably
in parallel, nor in parallel w/electric blower (45,000
scfm)
2. Turndown Limitations - Each steam-driven blower sized
for peak air demands but do not have adequate
turndown for low air demand conditions (i.e. triggers use
of air waste valve)
3. Undersize Redundancy - Electric blower is a backup for
emergencies and undersized for full range of air
demands, no redundant second electric blower
Condition of Below-Grade Aeration Piping
- ..
12
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AERATION SYSTEM LEAKS LEAD TO ADDITIONAL
STEAM/AIR DEMANDS (3/20/18)
FIS �I Y�
�C S'����W R1 ifM W Sy?
RANGE OF AERATION CONSIDERATIONS WHEN
DESIGNING NEW AERATION SYSTEM
BlowerBlower Capacity, Dedicated
Turndown Redundancy and Aerated Grit
Efficiency Blowers
Operational Improved
Flexibility Monitoring i Intentional
Control Relief
Unknown
Piping Air Flow More Efficient
Conditions
Improvement
13
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PRE-DESIGN
AWL
DRAFT LIST OF PRE-DESIGN
TECHNICAL MEMORANDA
• Tech Memo 1 - Business Case Analysis for Water Exchange
Alternatives
• Tech Memo 2 - Condition Assessment of Energy System &
Aeration/Secondary Systems
• Tech Memo 3 - Condition Assessment of Electrical &
Instrumentation Systems
• Tech Memo 4 - Design Criteria Development & Improvements
to Meet Current & Future Regulatory Requirements
• Tech Memo 5 - Business Case Analysis for In-Kind
Replacement & Other Alternatives
• Tech Memo 6 - 10% Pre-Design Report
1'
14
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DRAFT PROJECT SCHEDULE
2018
mmm®®mm
Internal Kick-Off Meeting March 29
Draft RFP Internal Distribution = May 29
Project Introduction to E&O Committee May 7
Project Introduction to Board June 7
RFP Advertisement June 8
RFP Submittal Deadline July 13
Interview&Consultant Selection August 8
Presentation to E&O Committee August 13
Presentation to Board September 6
Notice to Proceed for Consultant September 7
Planning and Pre-Design September 2018-February 2020
Final Design(Phase 1 Placeholder) February 2020-October 2021
Construction&Commissioning(Phase 1 Placeholder) October 2021-October 2024
QUESTIONS?
15
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