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HomeMy WebLinkAbout03.c. Review draft Position Paper to authorize the General Manager to execute a professional engineering services agreement in an amount not to exceed $844,000 with Brown and Caldwell for design of the Influent Pump Electrical Improvements, District Proj Page 1 of 19 Item 3.c. ,,eJkCENTRAL SAN CENTRAL SAN BOARD OF DIRECTORS POSITION PAPER CENTRAL CONTRA COSTA SANITARY DISTRICT DRAFT MEETING DATE: NOVEMBER 5, 2018 SUBJECT: REVIEW DRAFT POSITION PAPER TO AUTHORIZE THE GENERAL MANAGER TO EXECUTE A PROFESSIONAL ENGINEERING SERVICES AGREEMENT IN AN AMOUNT NOT TO EXCEED $844,000 WITH BROWN AND CALDWELL FOR DESIGN OF THE INFLUENT PUMP ELECTRICAL IMPROVEMENTS, DISTRICT PROJECT 7328 SUBMITTED BY: INITIATING DEPARTMENT: NANCY MOLI NA, ASSOCIATE ENGI NEER ENGI NEERI NG AND TECHNI CAL SERVI CES- CAPITAL PROJECTS REVIEWED BY: CRAIG H, MIZUTANI, SENIOR ENGINEER EDGAR J. LOPEZ, CAPITAL PROJECTS DIVISION MANAGER JEAN-MARC PETIT, DIRECTOR OF ENGINEERING AND TECHNICAL SERVICES ISSUE Board of Directors' (Board)authorization is required for the General Manager to execute a professional engineering services agreement in an amount greater than $100,000. BACKGROUND The Influent Pump Station is an essential and critical facility for daily operations. Without the influent pumps, wastewater cannot be lifted up to the downstream treatment processes or diverted to the storage basins for flow equalization. The influent pumps programmable logic controllers (PLCs)and variable frequency drives (VFDs) are outdated technology, installed over 20 years ago, and are becoming increasingly difficult to maintain. The VFDs are showing signs of wear and have experienced failures, as presented to the Board on May 3, 2018 for the replacement of the VFD for Influent Pump No. 1. The VFDs and PLCs are essential to the treatment plant for managing influent flows, particularly during wet weather events. Furthermore, the influent pump motors are in a dry pit room below grade that could be susceptible to internal flooding. Electrical improvements are recommended to improve reliability and resiliency of the station. Being de facto in the lowest point in our gravity collection system, without a fully functional and reliable Influent Pump Station, Central San will be at risk of wastewater overflowing out of the sewer system and spilling into the treatment plant and Grayson Creek if some of these critical components are not addressed and fail. With this project, a sixth influent pump will be added to provide redundancy. During high flows in the winter(over 200 million gallons per day(MGD)was recorded in 2017), all existing influent pumps were in service, which means that at that time Central San had no readily November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 27 of 62 Page 2 of 19 available standby pump in case of mechanical or electrical and controls failure. The inclusion of this sixth pump was planned in the original design, as provision for adding this pump were constructed both from a physical space and with the majority of piping already constructed. On August 31, 2018, a Request for Proposal (RFP)was publicly advertised on Central San's website and PlanetBids. Five (5)consulting engineering firms responded with qualified and responsive proposals.After evaluating the proposals based on qualifications, statement of approach, staff availability, and understanding of the project, staff invited the top three scoring consulting firms to participate in an oral interview. The three consulting engineering firms were Black and Veatch, Brown and Caldwell (B&C), and Kennedy/Jenks Consultants. Based on the combined score of the RFP and interview, B&C ranked as the top firm and is recommended for this project. B&C's scope of work includes a detailed investigation and assessment of the Influent Pump Station electrical systems such as VFDs, motor control centers, PLCs, and related electrical infrastructure.An evaluation of all project components will be performed, and recommendations will be provided on how to update and integrate with our existing electrical system. Pump capacity will be evaluated and the addition of a sixth pump will be addressed. B&C's design services will include the pre-design, detailed construction cost estimates, final design, and bid support services. Staff has also included two critical items under this project aimed to potentially lower operations costs and increase resiliency of the facility by including the following to B&C's scope: 1. Operations Optimization - B&C will be tasked to provide recommendations to help reduce operations and maintenance (O&M)costs associated with improving efficiencies at the facility. Influent pumping is often one of the top three highest electrical demand at a wastewater treatment plant. The scope will include creating algorithms focused on the most important, optimum operation of the Influent Pump Station and upstream Headworks. Data will be displayed on dashboard(s)showing such information as wetwell levels, pump speed, power demand, electrical costs, other critical data (amperage, vibration, bearing temperatures, motor temperature, etc.), and that data will be integrated with our computerized maintenance management system software database (CityWorks)to improve predictive maintenance, reduce reactive type maintenance, and prevent failure and to constantly measure performance. The goal is to find areas to lower O&M costs (power or maintenance to equipment) using "big data" analytics. 2. Resiliency Improvements -This task will evaluate and provide recommendations of modifications that will allow the pumping station to continue to operate during internal flooding conditions, including evaluating the type of motors (e.g. immersible vs. submersible), or adding a new automatic gate to isolate the pump intake between the wetwell and the drywell, or installing a dry pit room sump pump, and/or recommending other modifications. Depending on the extent and cost of providing an acceptable and cost-effective resiliency to flooding, some of the modifications could be implemented in the future when assets are being replaced or budget is available. ALT ERNAT IVES/CONSIDERATIONS Alternative 1 -The Board could elect to reduce the scope of the agreement(e.g. remove the optimization and/or resiliency tasks). This is not recommended since optimization is an important Central San Strategic Plan Goal and can result in future O&M savings. Flooding at critical facilities can happen, as Central San experienced several years ago when a pump casing broke and flooded a pump station. Alternative 2 -The Board could inquire about phasing the project: Phase 1) replace the VFDs; Phase 2) add the sixth pump; Phase 3) provide resiliency; and separately Phase 4) provide pump optimization and new PLC, or other combination or prioritization of the project elements. The VFD replacements and a sixth pump is a high priority due to the issues mentioned above, which also includes new influent pump PLCs, since modern VFDs have more information and controls compared to the existing units. With the recent Headworks Screening Upgrades, District Project(DP) 7327, the PLC and networking systems under the November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 28 of 62 Page 3 of 19 Plant Control System I nput and Output(1/O) Replacement, DP 7339, and the potential for optimization under this project, staff has combined the improvements to be designed together. Staff is recommending to include all VFDs, other PLCs, and optimization modifications (e.g. new servers for"big data") under this project since it is more cost effective and standardized compared to two or more separate projects. Therefore, separating the scope items is not recommended. Alternative 3 - Do nothing. Continue with current equipment and systems as is without this project. The facility has limited electrical redundancy for wet weather and bypass conditions. Therefore, electrical failures to equipment, as experienced last year, can have a major impact on the operations of the facility and could result in major flooding. The last VFD repair took several months to perform and test, which was accomplished during the summer months and not during high flows.Adding a sixth pump provides redundancy in case of pump mechanical or electrical failure, operations has run all five existing pumps during flows above 200 MGD. The treatment plant has received incoming wet weather flows exceeding 200 MGD, last occurrence in 2017. Therefore, this alternative is not recommended. FINANCIAL IMPACTS The agreement cost ceiling is $844,000, which includes preliminary design, final design, and bidding assistance services. This agreement also includes the two optional tasks (optimization task for$34,000, and resiliency task for$44,000)described above. This agreement will be funded under the Influent Pump Electrical Improvements, DP 7328, listed in the Fiscal Year(FY)2018-19 Capital Improvement Budget (CI B)on page 178 with a total estimated project budget of$4,748,000. A transfer of$200,000 from the Cl B Contingency will be required to fund this project. The additional funds are required to include the optimization and resiliency tasks, staff time, and additional PLCs design for the facility. The construction of the added PLC work will be paid for by the future budget for the Plant Control Systems 1/0 Replacement Project- Phase 1, Filter Plant, DP 7339, listed in the FY 2018-19 Cl B on page 181 with a total estimated project budget of$4,342,000. COMMITTEE RECOMMENDATION The Engineering and Operations Committee reviewed this subject at the meeting on November 5, 2018 and recommended approval of the agreement. RECOMMENDED BOARD ACTION Authorize the General Manager to execute a professional engineering services agreement with Brown and Caldwell in an amount not to exceed $844,000 for design of the Influent Pump Electrical Improvements, District Project 7328. Strategic Plan Tie-In GOAL TWO: Strive to Meet Regulatory Requirements Strategy 1 - Strive to achieve 100%permit compliance in air, water, land, and other regulations, Strategy 2- Strive to minimize the number of sanitary sewer overflows GOAL THREE:Be a Fiscally Sound and Effective Water Sector Utility Strategy 2- Manage costs November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 29 of 62 Page 4 of 19 GOAL FIVE:Maintain a Reliable Infrastructure Strategy 1 - Manage assets optimally throughout their lifecycle, Strategy 2- Facilitate long-term capital renewal and replacement, Strategy 3- Protect District personnel and assets from threats and emergencies GOAL SIX:Embrace Technology, Innovation and Environmental Sustainability Strategy 2- Evaluate Business Processes and Optimize Business Operations ATTACHMENTS: 1. Presentation November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 30 of 62 Page 5 of 19 INFLUENT PUMP ELECTRICAL IMPROVEMENTS, DI TRICT PROJECT7328 s Engineering and Operations Committee November 5, 2018 Nancy Molina, - Capital Projects Associate Engineer Edgar J. Lopez Capital Projects Division Manager S, Wnd PROJECT NEEDS OVERVIEW The Project focuses on following main scope areas: Replacement of the Influent Pump Station Variable Frequency Drives (VFDs) Upgrade electrical feed and MCC to comply with NFPA 70 E (arc flash) Update Controls and PLCs Add a sixth Influent Pump Evaluate and implement, if cost effective, redundancy and resiliency of operation during an internal flooding scenario Evaluate and implement, if cost effective, an optimization of the Influent Pump Station and Headworks operation to save energy and integrate with CMMS to minimize reactive maintenance using Big Data analytics 1 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 31 of 62 Page 6 of 19 PROJECT MAIN OBJECTIVES Resiliency: Reliability: Minimize disruption: Pumps will operate • Modernize electrical Construction when flooded and controls sequencing Quick recovery equipment VFD/PLC from flooding Distribute the replacement events electrical loads to staging Minimize multiple reduce points of Renovation during pumps out of failure on SWGR 16 Dry weather service Add a 6t" pump to increase wet weather capacity Pump station updated PLCs and Construction configuration Flood resiliency Modern vF�s instrumentation sequencing LOCATION OF PROJECT LEWJM if�� C' � 1 1'1i1+1t1 sli SWAM 7A ENV YM a Ph�'1f��l$9rS CM1414IFf�� 'p 4 � a -tea r• . ` 15 Sca OCU 4 2 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 32 of 62 Page 7 of 19 INFLUENT PUMP STATION yy Influent �e I l t •ump Gallery with Five Pumps Provision • ump No.6 DRY WEATHER PUMPING OPERATION -r a a, a .. re 4• rr..ee re I I I Mrl' I I I i �f Red Indicates equipment in Service Green Indicates equipment in Ready Standby Mode 6 3 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 33 of 62 Page 8 of 19 WET WEATHER PUMPING OPERATION ANNA ll� _ Red Indicates equipment in Service Green Indicates equipment in Ready Standby Mode PUMP NO. C SIZING ON PWWF CAPACITY yrs.a, 5 k BYPASS TO BASINS Primary 170 mgd 170 mgd TOSEOONDARIE$ Bypass 96 mgd 130 mgd STR C' Tota I 266 mgd 300 mgd PRIMARY SEDIMENTATION BYPASS SMUCTURE TO BASINS Improve resiliency,increase reliability,and minimize disruption 4 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 34 of 62 Page 9 of 19 PUMP OPERATION WHEN FLOODED — SUBMERSIBLE OPTION Submersible, •.to 11 HP,40 MGD • Submersible/immersible motors limited 250 HP SUBMERSIBLE MOTOR INFLUENT SCREENS INFLUENT DISCHARGE DIVERSION STRUCTURE PUMPS METER VAULT CHANNEL Improve resiliency,increase reliability,and minimize disruption PUMP OPERATION WHEN FLOODED — EXTENDED SHAFTS OPTION Motorswould •. MOTOR REPLACE enclosure for noise HOUSING MOTOR TO EXISTING ROOF 0 HVAC would need to be BEAMS I EXTENDED revised PUMP SHAFT Vibration building IT (COMPOSITE) require reinforcing structure 0 Single Composite INFLUENT SCREENS INFLUENT DISCHARGE DIVERSION STRUCTURE PUMPS METER VAULT CHANNEL Improve resiliency,increase reliability,and minimize disruption 10 5 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 35 of 62 Page 10 of 19 PUMP OPERATION WHEN FLOODED — ADDITIONAL PROTECTION Isolation gates op flooding One pump out of service instead of wet wel I out of service Large p pump brings flooding down quickly u PUMP ISOLATION' LARGE SUMP PUMP GATE INFLUENT SCREENS INFLUENT DISCHARGE DIVERSION STRUCTURE PUMPS METER VAULT CHANNEL Improve resiliency,increase reliability,and minimize disruption. PUMP STATION POWER DISTRIBUTION RELIABILITY in 0 • TIE •' TIE • 700HP �400HP ©700HP© No.4HP 700 No 5 No 6HP 1� No.1 No.2 No.3 Improve resiliency,increase reliability,and minimize disruption 12 6 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 36 of 62 Page 11 of 19 DESIGN SERVICES FOR INFLUENT PUMP ELECTRICAL IMPROVEMENTS VFDs for Influent Pumps . r l�i�w M Influent Pumps Influent Pumps Control AMLI 13 NFPA 7 - STANDARDS FOR ELECTRICAL SAFETY IN WORKPLACE F es et'' 1 rl IQ • r • m 17 • . 1■ IL ■ r . • SWGR 16AB k 1 r+., 1 ♦ ♦ 1 MAINT MAINT 1 "* 1 MODE MODE 1 1 1 EatonFreedom eedom arc-resistant SWITCH LIGHT Motor Control Center SWGR 16 Remote Breaker Control Panel Improve resiliency,increase reliability,and minimize disruption 7 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 37 of 62 Page 12 of 19 SAMPLEPLC EXISTING PLANT EXISTING PLANT NETWORK NETWORK DEVICE NETWORK RING M580 M58° Plan for redundancy: both PROCESSOR PROCESSOR PLC processors and RACK RACK network pathways HOT STANDBY LINK ETHERNET 1 0 RING Separate systems to reduce ETHERNET IORING 11 potential failure points X80 1/0 RACK X80 I/O RACK Provide security via r I DEVICE NETWORK RING managed switches and consistent network design a a UN U ry a d a U U Improve resiliency,increase reliability,and minimize disruption Al'I � 15 OPERATIONAL PUMP AND MOTOR MONITORING . . . . . accelerometers • 216. • - k UT ro 7iol V7.7 SRI' Improve resiliency,increase reliability,and minimize disruption 8 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 38 of 62 Page 13 of 19 PUMP AND MOTOR MONITORING — PUTTING THE DATA TO WORK -.interlocks) VIBRATION �, .D. (trend . TEMPERATURE DATA ConditionF_ CMMS MOTOR CURRENT DATA (maintenance correlation) . (predictive dL Improve resiliency,increase reliability,and minimize disruption r _ BIG DATA ANALYTICS = SMART UTILITY BENEFITS iNG WTA AMYTIcs V.0 Improve resiliency,increase reliability,and minimize disruption 9 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 39 of 62 Page 14 of 19 BIG DATA = MART UTILITY BENEFITS Operational Informed Workforce efficiency decisions optimization q ,k� Improve resiliency,increase reliability,and minimize disruption 19 OPTIMIZATION APPROACH 40 Connect business and 41 Define the 40 Choose the technology SCADA systems to create a vision and develop standards platform to perform real- time predictive analytics and integrate with CMMS AM Identify utility business Define use cases and analytics and operational user that will meet business and requirements operational needs to enable smart decision making Improve resiliency,increase reliability,and minimize disruption w.- 20 10 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 40 of 62 Page 15 of 19 BIG DATA ANALYTICS CASE STUDY 1 STABLE INFLUENT PUMPING REGIME Relation between screen control events and influent pumps level/ Bill L analysis Historical correlationflow control can improve operations r- Hydraulic upstream and downstream of IPS I Influent Modeling Dampen IPS response to level flow' ' -lu change in association with �i fluent screen cleaning 'rI - frequentoperation of influent screens can •mitigated by Number of screens in operation and dampening level control current flow rates can modify wet response in association well level/flow control settings to screenwith • • control velocity of flow through influent screens Improve resiliency,increase reliability,and minimize disruption rt . BIG ATA ANALYTICS CASE STUDY 2 COLLECTIONS SYSTEM: WET WEATHER FLOW PREDICTION AND MANAGEMENT Real-time analytic to determine the right time to start CEPT or CSO Hydraulic treatment facilities using weather forecast data, rainfall, and collection system flow data, and overall flow management model • Be on time and prepared for - mitigating high flows into a WWTP. Improve resiliency,increase reliability,and minimize disruption w- EYR] Hl.a:.A W 22 11 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 41 of 62 Page 16 of 19 BIG DATA ANALYTICS CASE STUDY 3 INFRASTRUCTURE STABILITY Historical asset failures may assist in predicting future modes Vibration . . . L System Installation dates, materials of construction,condition data from an asset management system reflectedAsset condition can be GIS to visualize the grouping of operational asset fa i I u res performance . . SCADA and Vibration Monitoring Historical failure data to provide field parameters modes may be that could indicate end of useful life predicted by monitoring asset data. Improve resiliency,increase reliability,and minimize disruption ._ _ .. 23 deft FUTURE DEPLOYMENT TO REST OF PLANT: INVESTMENT MILESTONES WITHOUT REWORK A staged approach to implementing Smart Utility allows you to implement new technology in phases to limit rework. PREDICTIVE AND 1 AWARENESS 2 ANALYTICS 3 PRESCRIPTIVE ANALYTICS 0• --wt 0>4 + - r * 02) Improve resiliency,increase reliability,and minimize disruption 112 4 12 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 42 of 62 Page 17 of 19 PROJECT APPROACH DURING DESIGN Task 1 Project Management Task 2 Pump Station Systems Task 3 VFD/MCC/PLC Replacement Planning Task 4 Construction Sequencing Task 5 Preliminary Design Task 6 Final Design&Bid Services Improve resiliency,increase reliability,and minimize disruption OVERALL PROJECT SCHEDULE Task 2018 2019 020 2021 0 Quarters 4 1 1 2 1 3 4 1 2 3 4 1 2 3 4 • Design with shutdowns Design IIIIIIIIIIIIIIIIIIIIIINNIN Bidding in mind Award and NTP Procurement Define clear constraints Shutdown and Planning OEM Misc.and Structural and in bid documents mechanical Switchgear Modifications Guide contractor Feeder Re-distribution Control System Programming through safe sequence PLC Installations of shutdowns MCC Replacement Vibrations Monitoring Installations Shutdown planning Pump 6 and VFD Pump Iand VFD early in construction Pump 2 and VFD Pump 3and VFD Be efficient: Take Pump 4and VFD advantage of schedule Wet Weather Hold Pump 5 and VFD Project Closeout 26 13 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 43 of 62 Page 18 of 19 PROJECT BUDGET The agreement cost ceiling is $844,000, which includes preliminary design, final design, and bidding assistance services. This agreement also includes the two optional tasks (optimization task for$34,000, and resiliency task for$44,000)described above. This agreement will be funded under the Influent Pump Electrical Improvements, DP 7328, listed in the Fiscal Year(FY) 2018-19 Capital Improvement Budget (CIB)on page 178 with a total estimated project budget of$4,748,000. A transfer of$200,000 from the CIB Contingency will be required to fund this project. The additional funds are required to include the optimization and resiliency tasks, staff time, and additional PLCs design for the facility. The construction of the added PLC work will be paid for by the future budget for the Plant Control Systems 1/0 Replacement Project- Phase 1, Filter Plant, DP 7339, listed in the FY 2018-19 CIB on page 181 with a total estimated project budget of$4,342,000. 27 ENGINEER'S SELECTION On August 31, 2018, a Request for Proposal (RFP)was publicly advertised on Central San's website and PlanetBids. Five (5) consulting engineering firms responded with qualified and responsive proposals.After evaluating the proposals based on qualifications, statement of approach, staff availability, and understanding of the project, staff invited the top three scoring consulting firms to participate in an oral interview. The three consulting engineering firms were Black and Veatch, Brown and Caldwell (B&C), and Kennedy/Jenks Consultants. Based on the combined score of the RFP and interview, B&C ranked as the top firm and is recommended for this project. w- 28 14 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 44 of 62 Page 19 of 19 BOARD ACTIONS AND RECOMMENDATIONS Staff recommends the following: Authorize the General Manager to execute a professional engineering services agreement with Brown and Caldwell in an amount not to exceed $844,000 under the Influent Pump Electrical Improvements, District Project 7328. 2 J9 QUESTIONS ' 30 15 November 5, 2018 EOPS Regular Committee Meeting Agenda Packet- Page 45 of 62