HomeMy WebLinkAbout14. Authorize agreement with HDR, Inc. for condition assessment and predesign of Steam and Aeration Blower Systems Renovations, DP 7349; and as-needed agreement with Carollo Engineers for peer review services Page 1 of 29
Item 14.
CENTRAL SAN CENTRAL SAN BOARD OF DIRECTORS
POSITION PAPER
MEETING DATE: DECEMBER 20, 2018
SUBJECT: AUTHORIZE THE GENERAL MANAGER TO EXECUTE (1)A
PROFESSIONAL ENGINEERING SERVICES AGREEMENT WITH HDR,
INC. (HDR) IN AN AMOUNT NOT TO EXCEED $2,590,000 FOR CONDITION
ASSESSMENTAND PREDESIGN OF THE STEAM AND AERATION
BLOWER SYSTEMS RENOVATIONS, DISTRICT PROJECT 7349; AND (2)
AN AS-NEEDED AGREEMENT WITH CAROLLO ENGINEERS, INC.
(CAROLLO) I N AN AMOUNT NOT TO EXCEED $300,000 FOR PEER
REVIEW SERVICES
SUBMITTED BY: INITIATING DEPARTMENT:
NITIN GOEL, SENIOR ENGINEER ENGINEERING AND TECHNICAL SERVICES-
PDS-ASSET MANAGEMENT
REVIEWED BY: DANEA GEMMELL, PLANNING AND DEVELOPMENT SERVICES DIVISION
MANAGER
EDGAR J. LOPEZ, CAPITAL PROJECTS DIVISION MANAGER
JEAN-MARC 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 professional
engineering services agreements in an amount greater than $100,000.
BACKGROUND
December 20, 2018 Regular Board Meeting Agenda Packet- Page 125 of 168
Page 2 of 29
At the June 7, 2018 Board Meeting, staff presented a detailed explanation of the drivers and elements
associated with the Energy Recovery and Blower Replacement Project in the current Fiscal Year(FY)
2018-19 Capital Improvement Budget (CI B). Central San's existing energy, aeration systems and
secondary process are well maintained and have performed reliably for many years. Many of these
facilities that were originally installed in the late 1970s and early 1980s, now require significant ongoing
maintenance attention, are based on complex outdated and less energy efficient technologies, and have
operational limitations such as limited turndown capabilities and redundancy. Furthermore, some of the
piping systems (air and steam) are showing signs of corrosion, metal fatigue and stress, and have
developed leaks.
The 2017 Comprehensive Wastewater Master Plan (CWMP) recommended renovation of the steam,
aeration systems, and the associated structural, electrical and instrumentation/control systems based on
their aging condition, with an improved reliable, flexible, and optimized system. However, before
proceeding with any type of renovation, the existing steam piping, valves, blowers, secondary treatment
process and related equipment will require a detailed assessment to determine condition, remaining life
and what improvements or replacement are required, and to develop business case evaluations (BCE) on
the best recommended approach for Central San. There are five individual and associated projects in the
10-Year Capital Improvement Plan (CI P)to address the above-mentioned issues related to energy,
aeration systems, and secondary processes. Due to the inter-dependency of each project element (as
seen in Attachment 1), it became apparent that these efforts should be combined at this time into a single
project for the condition assessment and preliminary design concept as decisions made regarding one
process area would have a direct impact and affect the other related processes. Therefore, these projects
were combined to create the newly renamed project"Steam Aeration Blower Systems Renovations"
(Project), DP 7349.
However, it is not the intent at this time to proceed with a single project to design and construct all the
elements. Phasing will be considered and evaluated with the CI P updated based on the condition
assessment findings of this Project. The Board will be presented with the preliminary findings prior to
moving forward with any detailed design effort.
Project Elements: Condition assessment is critical and several elements (1-5) require a detailed
evaluation. This Project is aimed at evaluating and coordinating the following elements (a detailed
description of the Project elements can be found in Attachment 2):
1. Boiler Feedwater System: The remaining useful life of the boiler feedwater system and all of its
components is not known. Also, due to lack of redundancy within the boiler feedwater system, any boiler
feedwater maintenance work triggers the need to temporarily shut down major plant facilities which impacts
plant operations and impacts the Operations & Maintenance budget.
2. Steam System: The existing steam system is an intricate system with complex interconnections and
interdependencies between the solids treatment and handling process, waste heat, and systems
connected to the secondary process aeration system. Previous capacity evaluations indicated that there
may not be adequate redundancy to meet peak day steam demands due to capacity limitations as a result
of boiler feedwater limitations. Thus, a detailed condition assessment of the steam system can identify
system improvements, evaluate alternatives for heat recovery, and develop an energy balance. In addition,
a recent auxiliary boiler shutdown revealed the development of cracks in the burner. This Project will
evaluate the auxiliary boiler's useful life and its feasibility to meet steam demands.
3.Aeration Blower and Piping System: The steam-driven blowers cannot operate reliably in parallel,
nor can they operate individually in parallel with the electric blower. When blowers are operated in parallel,
they go into a surge condition which can lead to catastrophic failure. Each steam-driven blower is sized for
peak air demands but does not have adequate turndown for low air demand conditions. The smaller
electric motor driven blower is not sized to meet peak demand and cannot be operated in parallel with the
December 20, 2018 Regular Board Meeting Agenda Packet- Page 126 of 168
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larger steam turbine blowers. Leaks in the aeration air piping (primarily associated with the buried air
headers) result in significant air losses.A condition assessment can evaluate the aeration system capacity
and its remaining useful life; determine cost-effective alternatives for blower replacement and address the
aeration leaks.
4. Secondary Treatment Process:A condition assessment of the secondary process consisting of the
aeration basins, secondary clarifiers, associated activated sludge processes and sludge pumping, is
needed to evaluate and recommend improvements (e.g. aeration system, mixed liquor flow splitter box,
anaerobic selector modifications, return activated sludge/waste activated sludge (RAS/WAS) sizing and
control modifications, clarifier blanket monitoring/control, etc.). If the Project is able to optimize the
secondary process, Central San can avoid the future expansion of the secondary clarifier as identified in
the CWMP.
5. Electrical Power Distribution System: The existing high voltage electrical system was designed for
facilities that in part no longer exist and may not be optimal for existing and planned future infrastructure.
Facilities and conductors will require assessment as they will likely be updated and some will need to be
replaced. The condition assessments will also evaluate, update, and find new optimal ways to distribute
power around the treatment plant to provide a safe, robust system in the future, determine remaining life
and improvements to the electrical distribution system. Recently, the plant experienced a major feeder
cable failure associated with Substation 82 and had to initiate emergency repairs; this Project will evaluate
these and others feeders.
6. Future Nutrient Reduction Impacts: On April 9, 2014, the San Francisco Bay Regional Water Quality
Control Board issued Order No. R2-2014-0014, Waste Discharge Requirements for Nutrients from
Municipal Wastewater Discharges to San Francisco Bay(Watershed Permit). In response to the
Watershed Permit, the Publicly Owned Treatment Works are working collectively under the joint powers
agency, Bay Area Clean Water Agencies (BACWA). While these requirements are well into the future,
they will impact the secondary treatment processes, thus, this Project will need to consider these potential
future requirements and be flexible enough to work with future regulatory requirements and water quality
needs while evaluating improvements and potential upgrades.
7. Water Exchange Project: While the Water Exchange Project would be implemented as an
independent project and would be funded mostly in part by other agencies, it will likely impact the
secondary treatment processes, thus, this Project will need to consider the Water Exchange and its
requirements and be flexible enough to address potential future water quality needs.
Overall Project Approach -The Project includes a significant amount of planning, condition assessment,
BCEs, and predesign work to ensure any improvements are made to meet current and future Central
San needs. Evaluations will be conducted to establish design parameters for each system/process and
associated equipment. See Attachment 3 for an outline of all major project elements and its drivers to be
addressed. This Project will include a detailed condition assessment and predesign that will:
•Assess the condition and remaining useful life of each project element
• Confirm the most cost effective and reliable energy recovery and aeration system replacement or repair
alternative
• Prepare 10% technical and cost estimates
• Prepare BCEs for all major options to support decisions
As-Needed Peer Review- The Project may generate the need to make some major decisions, such as;
1)what to do with the steam system (rehabilitation, replace in kind, or convert to generate heat to power); 2)
stay with steam blower or convert to electric driven blowers; 3) renovate, replace, or upgrade the electrical
distribution systems; or 4)the extent of the modifications, if any, to the secondary process/activated sludge
process. In addition, a"Do Nothing" alternative will be evaluated. When the Project was presented to the
Board on June 7, 2018, some of the Board members expressed the desire to conduct an independent
December 20, 2018 Regular Board Meeting Agenda Packet- Page 127 of 168
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"Peer RevievJ' or"Value Engineering" of the decisions and BCEs being presented. To address that
request, staff is proposing to hire an independent team of experts to conduct a peer review of those major
decisions to make sure they are well developed and economically sound.
Consultant Selection: On June 12, 2018, a Request for Proposal (RFP)was publicly advertised and
four 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 all four consulting firms to participate in an oral interview presentation. The four
consulting firms were HDR, Carollo/Black& Veatch, Brown and Caldwell, and CDM Smith. HDR ranked
as the top firm and is recommended for this project. Staff selected the second ranked firm, Carollo, to be
the consultant leading the peer review, but their team will include subject matter experts (SME)from other
firms and academics chosen by Central San based on technical, consensus building, and constructability
expertise.
The scope of the HDR agreement will include the following tasks: 1) Condition Assessments, 2) Design
Criteria Development and Recommended Improvements, 3) BCEs for In-Kind Repair, Replacement, and
Other Alternatives, 4) BCEs for Water Exchange Alternatives, and 5) Predesign Report and Cost
Estimates.
CEQA
Staff has concluded that this project is exempt from the California Environmental Quality Act (CEQA)
under Section 15262 of Central San's CEQA Guidelines, since it allows 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 of the tasks
authorized herein to determine the need for any additional CEQA documentation.
ALTERNATIVES/CONSIDERATIONS
1. The Board may elect not to proceed with the peer review and decline the services. The benefits of a
peer review include the enhancement of the credibility of project decisions and validation of critical
decisions that are recommended by an independent third party. The Peer Review team of SMEs that
will be conducting the peer review workshops were chosen by Central San based on technical
expertise, consensus building expertise, and constructability or project phasing. If the Board desires
to conduct a peer review of this potentially large project, staff recommends that the time to conduct
such effort is during the early stage, when alternatives and BCEs are prepared and presented.
Therefore, staff would recommend that the peer review be included at this time.
2. The Board may elect to postpone the 10% predesign work to a future fiscal year. However, this is not
recommended as this work is necessary for the public health, safety, security, and treatment plant
facilities and infrastructure needs as stated in the Project. This alternative would delay the
replacement of deteriorated infrastructure and would likely increase the overall cost of any project
element and risk of failures at the facilities. Therefore, this alternative is not recommended.
FINANCIAL IMPACTS
HDR's total agreement fee for the proposed scope of work is $2.59 million, which is about 2.3% of the
estimated overall total project costs considering the various condition assessments needed and identified
in the CWMP and included in the 10-Year Cl P (see Attachment 3 for project and budget details). Final
design services are not currently budgeted under this agreement at this time. Staff would likely not
implement all the elements in a single project, but phase with multiple projects. Central San will negotiate
the final design services fee with HDR once this initial phase of the Project is completed and a scope and
budget is finalized and authorized by the Board. The as-needed peer review cost with Carollo is expected
December 20, 2018 Regular Board Meeting Agenda Packet- Page 128 of 168
Page 5 of 29
to not exceed $300,000 which comprises other experts from academia and other firms including Black&
Veatch, AECOM, and Hazen and Sawyer.
COMMITTEE RECOMMENDATION
The Engineering and Operations Committee reviewed this matter on December 10, 2018, and
recommended approval of the agreements.
RECOMMENDED BOARD ACTION
Staff recommends the following:
1. Authorize General Manager to execute a professional engineering services agreement with HDR,
I nc. in an amount not to exceed $2,590,000 for condition assessment and predesign of the Steam
and Aeration Blower Systems Renovations, District Project 7349; and
2. Authorize the General Manager to execute an as-needed agreement with Carollo Engineers, I nc. in
an amount not to exceed $300,000 for Peer Review Services.
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
GOAL THREE: Be a Fiscally Sound and Effective Water Sector Utility
Strategy 2- Manage costs
GOAL FOUR: Develop and retain a highly trained and innovative workforce
Strategy 3- Meet or exceed industry safety standards
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 1 -Augment the region's water supply, Strategy 2- Reduce reliance on non-renewable energy, Strategy 3-
Encourage the review and testing of technology to optimize and modernize business operations
ATTACHMENTS:
1. Project Cost Estimates
2. Detailed Project Elements Descriptions
3. Project Elements and Drivers
4. Presentation
December 20, 2018 Regular Board Meeting Agenda Packet- Page 129 of 168
Page 6 of 29
ATTACHMENT 1
STEAM AND AERATION BLOWER SYSTEMS RENOVATIONS PROJECT
DISTRICT PROJECT 7349
Project Cost Estimates
DP Budget-to- CIB Total Project
No. Project Name Date Pae FY 2018-19 FY 2019-20 Cost
Energy Recovery and
7349 Blower $300,000 168 $1,200,000 $3,713,000 $60,150,000
Replacement
CIP Secondary Treatment $3,840,000
Hydraulic Improvements
Secondary Clarifier
CIP Mechanical $22,400,000
Replacement
CIP Standby Generator $5,150,000
Expansion
CIP Electrical Improvements
to Sub 82 and other
MCC, Substations (Part $20,000,000
of Annual Infrastructure
Replacement Project
Total $111,540,000
STEAM AND AERATION BLOWER SYSTEMS RENOVATIONS PROJECT
DISTRICT PROJECT 7349
Energy Recovery and Blower
Replacement Project Cost Estimates
Phase Budget-to-Date FY 2018-19 FY 2019-20 Future FYs Total
Planning $300,000 $1,200,000 $1,030,000 $0 $2,530,000
Design $0 $0 $2,683,000 $3,713,000 $6,396,000
Construction $0 $0 $0 $51,224,000 $51,224,000
FY Total $300,00 $1,200,000 $3,713,000 $54,937,000 $60,150,000
December 20, 2018 Regular Board Meeting Agenda Packet- Page 130 of 168
Page 7 of 29
ATTACHMENT 2
DETAILED PROJECT ELEMENTS DESCRIPTIONS
PROJECT ELEMENTS DESCRIPTIONS:
Condition assessment is critical and several elements (1-5) require a detailed
evaluation. This Project is aimed at evaluating and coordinating the following elements:
1. Boiler Feedwater System: The boiler feedwater system is from the 1970s and
1980s. The single closed loop boiler feedwater system is extensive and complex. It
must meet the plant's steam generation requirements and respond to frequent varying
operating conditions from all three concurrent steam generation sources: 1) the two
Multiple Hearth Furnace (MHF) waste heat boilers; 2) the cogeneration waste heat
boiler; and 3) the two auxiliary boilers. Due to additional steam demands, the boiler
feedwater system is now operating at much higher pressure than what the system was
originally designed in 1980s which results in capacity limitations. Another important fact
to note is that the operating pressure of the boiler feedwater system has changed over
time and not all components are rated optimally for the current operating conditions
which creates some risk and safety concerns.
Condition assessment needs and concerns with the Boiler Feedwater System: The
remaining useful life of the boiler feedwater system and all of its components is not
known. Furthermore, due to lack of redundancy within the boiler feedwater system, any
boiler feedwater maintenance work triggers the need to temporarily shut down major of
facilities. In one recent instance, this included shutdown of the entire boiler feedwater
system, all four boilers, multiple hearth furnace (MHF), cogeneration unit, steam-driven
turbine aeration blowers, and other equipment.
2. Steam System: The existing steam system is also aged and an intricate system with
complex interconnections and interdependencies between the solids treatment and
handling process, waste heat, and steam systems with the secondary process aeration
system. Due to this complex interconnection, any upsets, shutdowns, and process
variability in handling and processing the solids has a direct impact on the aeration
blower's ability to produce sufficient air volume and pressure to meet the dissolved
oxygen needs of the biological process. Similarly, major changes or upsets in the
operation of the aeration system may impact operation of the steam system, steam
generation equipment, and boiler feedwater systems.
Condition assessment needs and concerns with the Steam S sy tem: Previous capacity
evaluations indicated that there may not be adequate redundancy to meet peak day
steam demands due to possible auxiliary boiler capacity limitations as result of existing
boiler controls and/or boiler feedwater system limitations. Thus, a detailed condition
assessment of the steam system can identify steam system improvements, evaluate
alternatives for a new heat recovery system, and develop an energy balance.
December 20, 2018 Regular Board Meeting Agenda Packet- Page 131 of 168
Page 8 of 29
Attachment 2
Detailed Project Elements Descriptions
Page 2 of 4
In addition, the auxiliary boilers which are required to produce steam when steam
demand is not met from the cogeneration boiler and/or the MHF boilers, have aged.
Following observations made during a recent shutdown revealed the development of
cracks in the burner. Discoloration can also be seen from gas burning between
refractory and burner plate. A condition assessment will evaluate the auxiliary boiler's
useful life and its feasibility to meet steam demands.
3. Aeration Blower and Piping System: The aeration system consists of two steam
turbine driven centrifugal blowers and one electric driven blower. The two steam-driven
aeration blowers, installed in 1974, utilize steam from the waste heat and auxiliary
boilers. The electric engine-driven blower, installed in 1983, utilizes electricity generated
from the natural gas cogeneration system and/or from the electric utility PG&E.
Air pressurized by these blowers is conveyed via steel piping to the aeration basins for
the activated sludge biological treatment. Air produced by these blowers is also used for
channel aeration of treated effluent for dissolved oxygen requirements in the discharge
permit and also is piped to the pre-aeration tank for use for the aerated grit removal
process.
Condition assessment needs and concerns with the Aeration System: The steam-driven
blowers cannot operate reliably in parallel, nor can they individually in parallel with the
electric blower. Each steam-driven blower sized for peak air demands but do not have
adequate turndown for low air demand conditions.
Leaks in the aeration air piping (primarily associated with the buried air headers) result
in significant air losses. A condition assessment can evaluate the aeration system
capacity and its remaining useful life and determine cost-effective alternatives for blower
replacement and addressing the aeration leaks.
4. Secondary Treatment Process: The secondary process consists of a conventional
activated sludge biological treatment process with four serpentine rectangular aeration
basins. Mixed liquor (a blend of primary effluent flow and returned activated sludge
(RAS)) are first introduced to an anaerobic selector zone equipped with surface mixers
for biological phosphorus removal. The flow then is distributed via concrete channels to
the aeration tanks (referred to as AN Tanks at Central San).
Air produced by the aeration blowers to each tank via air piping and then routed below
the water surface where it is distributed below the tank false floor that is outfitted with
ceramic disk diffusers. The false floor houses the plenum that allow air to be distributed
to the process flow via the fine bubble generated by the ceramic disk diffusers.
Condition assessment needs and concerns with the Secondary Treatment Process: A
condition assessment of the secondary process is needed to evaluate and recommend
improvements (e.g. mixed liquor flow splitter box, anaerobic selector modifications,
December 20, 2018 Regular Board Meeting Agenda Packet- Page 132 of 168
Page 9 of 29
Attachment 2
Detailed Project Elements Descriptions
Page 3 of 4
RAS/waste activated sludge (WAS) sizing and control modifications, clarifier blanket
monitoring/control, etc.). If the Project is able to optimize the secondary process, it can
avoid the future expansion of the secondary clarifier as identified in past projects.
The existing anaerobic selector was constructed within existing channels and is limited
in its volume and retention time. In addition to potential hydraulic short-circuiting, the
retention time to each aeration tank varies and may be less than optimal for an
anaerobic selector. It is possible that existing tank configuration limits the effectiveness
of the selector under different flow and loading conditions.
The aeration air piping, diffusers, mixed liquor flow hydraulic distribution between the
A/N Tanks and then to two secondary clarifier Quads will be evaluated as well as tank
operating depth, process performance, RAS/WAS rates and other process controls.
5. Electrical Power Distribution System: Electrical Substation 82 (Sub 82) was
installed in 1974 and the majority of the components are from the original installation.
Sub 82 is the main electrical substation at Central San where PG&E is connected to the
internal electric grid that feeds the plant for its electrical power needs and therefore an
essential hub. There is a vast infrastructure of buried high voltage 12kV cables that
distribute power between the substations and from Sub 82 to the rest of the plant, and
other offices such as the Headquarter Office Building (HOB) and Plant Operations
Building (POB) facilities. Most high voltage distribution cables were installed around 40
years ago. Sub 82 is also connected to the plant electrical grid system which also
receives power for the co-generation system.
Condition assessment needs and concerns with the Electrical Power Distribution
System:The existing high voltage electrical distribution system was designed for
facilities that no longer exist and may no longer be optimal for existing and planned
future infrastructure. As aging electrical gears, facilities and conductors will require an
assessment as they will likely be updated and some will need to be replaced. The plant
recently experienced some major failure in the cabling associated with Sub 82 and had
to initiate emergency repairs to resume safe and reliable operation. The condition
assessment will also evaluate, update, and find new optimal ways to distribute power
around the treatment plant to provide a safe robust system in the future, the remaining
useful and improvement of the electrical distribution system will be assessed.
6. Future Nutrient Reduction Impacts: Nutrients in the San Francisco Bay (SF Bay)
are a growing concern for the Bay Area water quality community. On April 9, 2014, the
San Francisco Bay Regional Water Quality Control Board issued Order No. R2-2014-
0014, Waste Discharge Requirements for Nutrients from Municipal Wastewater
Discharges to San Francisco Bay (Watershed Permit). In response to the Watershed
Permit, the Publicly Owned Treatment Works (POTW) are working collectively under
the joint powers agency, Bay Area Clean Water Agencies (BACWA). Central San
acknowledges the waste discharge requirements for nutrients from municipal
wastewater discharges will take place in the future and possibly requiring to reduce the
December 20, 2018 Regular Board Meeting Agenda Packet- Page 133 of 168
Page 10 of 29
Attachment 2
Detailed Project Elements Descriptions
Page 4 of 4
load in future permits. While these requirements are well into the future, they will
impact the secondary treatment processes, thus, the Project will need to consider
these potential future requirements and be flexible enough to work with future
regulatory requirements and water quality needs while evaluating upgrades and
improvements that should be done earlier.
7. Water Exchange Project: Central San is evaluating the Water Exchange Project to
facilitate regional collaboration, augment water supply and maximizing resource
recovery, reduce effluent loads to Suisun Bay, and overall sustainability. Upgrades will
take in account Central San's plan for implementing the Water Exchange project and
avoid constructing stranded assets. While this Water Exchange Project would be
implemented as an independent project and would be funded mostly in part by other
agencies, it could also impact the secondary treatment processes, thus, the Project will
need to consider this future project and its requirements and be flexible enough to
address the water quality needs while evaluating upgrades and improvements that be
done earlier under this Project.
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ATTACHMENT 3
STEAM AND AERATION BLOWER SYSTEMS RENOVATIONS PROJECT
DISTRICT PROJECT 7349
Project Elements and Drivers
Driver(s)
Element Project Elements
# Replacing Aging Capacity Regulatory Sustainability and
Infrastructure Limitations Compliance Energy Optimization
1 Boiler Feedwater System
2 Steam System
3 Aeration System
4 Secondary Process
5 Electrical Distribution System
6 Future Nutrient Reduction
Impacts
7 Water Exchange Project
December 20, 2018 Regular Board Meeting Agenda Packet- Page 135 of 168
Page 12 of 29
� qw Attachment
ENERGY RECOVERY AND BLOWER
_ REPLACEMENT PROJECT
DP 7349
Board Meeting
- December 20, 2018
Jean-Marc Petit
Director of Engineering & Technical Services
1115433TO,11114-7-M
Y pro est
/ Ren001" th
�s
l
STEAM AND AERATION BLOWER SYSTEMS
RENOVATIONS PROJECT
DP 7349
1
December 20, 2018 Regular Board Meeting Agenda Packet- Page 136 of 168
Page 13 of 29
PROJECT BACKGROUND
• Project elements identified over past 12 years in Capital Improvement
Budgets (CIB)and reaffirmed as part of Comprehensive Wastewater Master
Plan (CWMP).
• Project was introduced to the E&O Committee on May 7, 2018 and to the
Board on June 7, 2018.
• After Board approval, a Request for Proposal (RFP)was publicly advertised
and four(4)consulting engineering firms responded.
• After evaluating proposals based on qualifications, statement of approach,
and staff availability, staff invited all four consulting firms to participate in an
oral interview presentation.
• The four consulting firms were HDR, Carollo/Black&Veatch, Brown and
Caldwell, and CDM Smith.
• HDR ranked as the top firm and is recommended for this project.
• Staff selected the second ranked firm, Carollo,to be the consultant leading
the peer review, but will include subject matter experts(SME)from other firms
and academics chosen by Central San based on technical, consensus
uilding, and constructability expertise. `
r 3
HDR TEAM SELECTED FOR THIS PROJECT
I IL n It
Holly Kennedy,PE Craig Olson,PE Mike Falk,PhD,PE Graham Bell,PhD,PE,
Principal-in-Charge Project Manager Process Engineer FNACE
Condition Assessment Lead
Dan Sampson Doug McHaney,PE JB Neethling,PhD,PE Brian Boitano,PE
Steam Lead Electrical Lead Process Lead Project Engineer
I�
CENTRALSAN
_tea— d
2
December 20, 2018 Regular Board Meeting Agenda Packet- Page 137 of 168
Page 14 of 29
OVERALL PROJECT OBJECTIVES
• Ensure employee safety
• Ensure reliable operation of the
steam, aeration and other related
systems over next 20+years
• Ensure reliable NPDES permit
compliance (Current and Future)
• Ensure reliable Title permit V
compliance (Current and Future)
• Reduce Operations and Maintenance
(O&M)cost(e.g.; reduce chemical
and energy usage and labor cost
associated with maintenance and
frequent repairs)
� 5
PROJECT NEED STATEMENT
1.Central San's Energy Production and Steam & Secondary Processes
are extensive, interdependent&complex.
2.Detailed condition assessments by specialized experts is key to
understanding the remaining useful life of critical equipment&
preparing the baseline alternative cost.
3.Through Central San's great maintenance program, facilities are still in
service while already beyond their typical useful life. Need to have a
strategy for addressing issues as they arise and the future needs to
replace them (in-kind or not).
4.Deciding on the optimal, cost-effective heat energy recovery is an
important milestone ahead of detailed alternatives analysis.
5.Project needs to balance near-term upgrades&optimization with long-
term strategies (e.g. nutrient removal &water exchange).
r 6
3
December 20, 2018 Regular Board Meeting Agenda Packet- Page 138 of 168
DRIVERS FOR STEAM AND AERATION
SYSTEMS RENOVATIONS PROJECT Now
Primary Drivers:
Condition
Assessments/ Replace Aging/ Address
Remaining Unreliable Assets Equipment
Useful Life Redundancy
1AL JJ
CENTRAL SAN
Condition
Assessments/ Replace Aging/ Address
Remaining Unreliable Assets Equipment
Useful Life Redundancy
Improve Energy Optimization/ Prepare forWater Exchange/
Efficiency/ Performance/ Future Nutrient
Sustainability Water Quality
Removal
S
CENTRALSAN
Page 16 of 29
ENERGY PRODUCTION AND USES AT CENTRAL SAN ARE
EXTENSIVE, COMPLEX, AND INTERDEPENDENT BETWEEN
LIQUID, SOLIDS, AND ENERGY SYSTEMS
These critical systems are aging, becoming less reliable, impacting
operational reliability and regulatory compliance, and requiring
increased maintenance.
SIEN N4!jERAfi1,0N,, BUOH
GYSTERS
, 6VATIONS, PROJECT
I
Movie Clip of Steam System click here.
9
CENTRAL SAN
dr
STEAM SYSTEM IS CRITICAL FOR THE
SECONDARY PROCESS
Furnace Exhaust D Waste Wet Induced
ry Heat �♦ Draft
Scrubber Boilers Scrubber Fan
Scrubber Water
to Primary
Effluent
Steam Piping Steam Pre-Aeration
Cake Turbine
Lm.ue
iple Blowers
-1 1Landfill gasces Electricit Waste
to Plant St m A/N Tanks
Standby Heat Us rs
Power Boiler
Potable Feeds: Facility
water Boiler
Feed MHF Boilers Mixed Liquor
Auxiliary
Water Cogen Boiler Eleco-mny Metef Cogen Boilers Channels
Aux.Boilers from Grid Turbine
Final Effluent
Ash •• �h
Handling
System Natural sas mct.r �•�•
♦� Future Needs
ate
INutrient
Exchan Removal)
CENTRAL SAN
5
December 20, 2018 Regular Board Meeting Agenda Packet- Page 140 of 168
Page 17 of 29
CENTRAL SAN SECONDARY TREATMENT
PROCESSES
1�11111akLIlU� i = .
ILZ. e
CENTRAL SAN
D STEAM &AERATION BLOWER SYSTEMS RENOVATIONS PROJECT ELEMENTS
:tT
K �i :�■�r.y� a Steam Generation
Boiler Feed Water
i it �1
-VIA
I Steam&
1 r
Condensate
• ,. -. . _
k., Or Piping
r
IL _
WAW
0 0, u jeo
i 1 fliiaa
i 4 }Sti it J
' Optimize Selector New Diffusers&Piping
&Aeration Tank Rehab I`; Dedicated
.. T,410PINMl
Aerated Grit
Re-Use Blower Building Blowers
for New Blowers?
SUB 52 Electrical Upgr .
6
December 20, 2018 Regular Board Meeting Agenda Packet- Page 141 of 168
Page 18 of 29
0 SECONDARY TREATMENT/ELECTRICAL CONSIDERATIONS
SUB 82
Electrical Upgrades
6 I (-
Mixed Liquor y
Hydraulic
Splitter Box - � �Gw-
Rehab Clarifiers
SUB 33&34 and RAS/WAS
Electrical Upgrades
I :�n11111.1 lit ,.,
.I I�
CENTRAL SAN
0 'LANNING FOR WATER EXCHANGE PROJECT ELEMENTS
SUB 82 1
Electrical Upgrades \\�'
._ 20 MGD Water Exchange:
Biological Nitrogen Removal(BNR)using:
BAF,or membrane Bioreactors(MBR),or Tertiary w
Membranes,or AquaNereda°Granular Activated
Sludge+Microfiltration+Split Stream Reverse
Osmosis
I
i 1@1111
1 41111 ��
Divert 20 MGD Conventional Activated Sludge r"
14
CENTRAL SAN
7
December 20, 2018 Regular Board Meeting Agenda Packet- Page 142 of 168
Page 19 of 29
0 PLANNING FOR FUTURE NUTRIENT REMOVAL BACWA LEVEL 1
SUB 82 +
Electrical Upgrades
ti� it
❑
CEPT
oil
5 95111
Seasonal Nutrient '� rig
- Optimize Selector Removal:New
Diffusers&Piping& i - �•
Aeration Tank Rehab
Re-Use Blower Building
for New Blowers? SUB 52 Electrical Upgrades
0 LANNING FOR FUTURE NUTRIENT REMOVAL BACWA LEVEL
SUB 82 ° Contaminated Soil
Electrical Upgradis, Future Nutrient Relocation
Future Clarifiers? Removal Tanks - ,
O New
Blower
❑ Building? r,
5 00 -
r
CEPT
00I �f
I.
+fJ` Convert to Nutrient
Optimize Selector Removal:New
Diffusers&Piping&
Aeration Tank Rehab _ Primary Expansion?
Re-Use Blower Building 1-4.0111
for New Blowers? SUB 52 Electrical Upgrades
8
December 20, 2018 Regular Board Meeting Agenda Packet- Page 143 of 168
Page 20 of 29
PROJECT ELEMENTS TO BE EVALUATED
SUB 82 Contaminated Soil
Electrical Upgrades Future Nutrient Relocation
Water Exchange Future Clarifiers? Removal Tanks _ Steam
Generation
New Boiler Feed Water
O Blower
s ❑O Building? Steam&
Condensate
Mixed Liquor Rehab Clarifiers Piping
Hydraulic Add
Splitter Box Generator
O CEPT
SUB 33&34 r\../ J u
Electrical Upgrades i a .a I il,
12" New Diffusers&Piping
Optimize Selector rl &Aeration Tank Rehab y . Dedicated4
rAerated Grit
i Re-Use Blower Building r Primary Expansion Blowers
•' for New Blowers? -
SUB 52 Electrical Upgrades
MAIN AREAS OF FOCUS OF PROJECT
se
6 1 R
Lo-
1
6 3
2
a`_ o b
BOILEREEED HEAT RECOVERY STEAM AND AERATION AERATION BASINS SECONDARY ELECTRCIALAND
and STEAM BLOWERS
WATER SYSTEM CONDENSATE (4)ANDAIR CLARIFlERS(R)& CONTROLS
PRODUCTION STEAM N COPIPINDENSTEMATE (STEAM& PIPING RAS/WAS SYSTEMS
ELECTRIC) PUMPING 18
CENTRAL SAN
9
December 20, 2018 Regular Board Meeting Agenda Packet- Page 144 of 168
Page 21 of 29
1 1 BOILER FEED
WATER SYSTEM
Major Components
• Ion Exchange Softeners -
• Deaerator
• Chemical Feed Systems
• Boiler Feed Water Pumps
Vulnerabilities/Concerns
• Safety(Operating at higher pressure
than designed pressure)
• Capacity/redundancy
ji,Reliability(complexity and highnumber of valves,and components)
Corrosion/fatigue
19
2 I HEAT RECOVERY He
STEAM PRODUCTION y
Major Components ®�
• Two Furnace Waste Heat
Boilers
• Two Auxiliary Boilers
• One Cogeneration Waste Heat -
Boiler
Vulnerabilities/Concerns
• Corrosion/Aged Equipment
'r
• Reliability(complexity and
high number of valves and
components)
• GHG(when steam from
auxiliary boilers is used)
10
December 20, 2018 Regular Board Meeting Agenda Packet- Page 145 of 168
Page 22 of 29
3 1 STEAM & CONDENSATE
PIPING SYSTEM
Major Components
Condensate:storage,pumping,,
low and high pressure piping
of
• 1,500 feet of steam piping
(two steam headers)
• 1,500 feet of condensate
piping
• Over 100 major valves
• Over 750 smaller valves
VuinerapiIitiezy%,,vncerns �-
• Safety
• Corrosion/fatigue F •'
• Reliability
• Seismic
4 AERATION BLOWERS
.z�r
Major Components
• Steam and Electrical
Blowers/Aeration System
• Valves • Mounts
• Controls • Casing
• Nozzle Blocks • Shell -
• Bearings • Lubrication
Vulnerabilities/Concerns
• Complex
• Parallel Operation
• Turndown
• Redundancy
• Discharge air piping leaks
11
December 20, 2018 Regular Board Meeting Agenda Packet- Page 146 of 168
Page 23 of 29
5 1 AERATION BASINS &
AIR PIPING
Major Components "�-
• Main air header between Pump& •■ -�_ — --
Blower Building and Aeration Basins
• Four Aeration Basins(A/N Tanks) — tie f u
• Air Disk Diffusers and Plenum
• Air Distribution Piping and Control Valves
Vulnerabilities/concerns _
• Air Piping Conditions 1IT
Capacity/Redundancy of Activated '.`
�r a rr :=_ + iiii
Sludge ��—
• Readiness for Future Nutrient _
Removal
I'.
• Corrosion/fatigue kFi
• Conversion to seasonal biological
nutrient removal
r fig$
23
C 1 SECONDARY
TREATMENT
Major Components
• Secondary Clarifiers
• Two quads of four tanks each,
eight total
• Mechanisms and drives � IITlllla llld
• Mixed liquor distribution channels
• RAS/WAS/Scum Pumping
Vulnerabilities/Concerns
• Capacity/redundancy
(Wet Weather)
• Hydraulic and Solids Load
Distribution
i -
• Age and condition of mechanisms
and drives �,•-t°�
• Corrosion/fatigue
• Seismic(sloshing)
12
December 20, 2018 Regular Board Meeting Agenda Packet- Page 147 of 168
Page 24 of 29
�F
71 ELECTRICAL & -
CONTROLS SYSTEMS T
Major Components
• Substations 82,73,etc. m'
• Standby generation
• MCCs
• Cable trays
• Conductors and other
electrical components
Issues MCC 4MI.1361
Bhbb
• Safety(arc flash)
• Age and condition of ""n°
e�>r
electrical system M' CAI,4MI
• Readiness for future '""`•'"'1M
expansion MCC 3361,=2
MCC VF1,d N
MCC 39311,]913
MCCITC.,176
Mcc W a,I.ah s MCC 6M:M6
6wflt55e•r Bld• NCC e1IMMMMt1,BIC3
MCC 7361.81.tM44,73UI.
NYMC 53A,53M 811G 6P 7363!\�,T9Cwnh Gir,T3CFG 25
NCC 52J1.52JY. MCC 73U3
SOME CONCERNS & OPTIMIZATION
OPPORTUNITIES IDENTIFIED BY STAFF
1
13
December 20, 2018 Regular Board Meeting Agenda Packet- Page 148 of 168
Page 25 of 29
BOILER FEED WATER VALVE REPLACEMENT
TRIGGERS MAJOR PLANT COORDINATION IN 2018
➢ Shutdown Aeration Turbines �
➢ Transition to Electric Blower
➢ Shutdown Cogen & WHB _ e�
(i.e. import PG&E power) may. c'
➢ Shutdown Boilers & Boiler
Feed Water System
➢ Perform Repairs
➢ Start-up All SystP- 000
CONDITION OF BELOW-GRADE AERATION
PIPING NEEDS TO BE EVALUATED
firr. :•-
7,7J
rOF
28
i'
14
December 20, 2018 Regular Board Meeting Agenda Packet- Page 149 of 168
dn
all-
Steam Driven Boilert '_.. - Steam Piping above
Feed Water PumpsrFurnace WHB
Steam Piping in Tunnels
Steam Driven Pumps& from SCB to Pump&
Other Steam Piping in SCB Blower Building
CENTRALSAN
• •
.,�Steam Turbine Blowers Electric Blower
Oil Lubrication
System
- All.
t � Piping,Pumps,etc.for Air Piping associated with
r
- Steam Turbine Blowers Electric Blower
,
Liter+
,1• I II
1 � f
CENTRALSAN
�- •- 1 1 '-• :•. • • � •- •. .•- 1 • •:
Page 27 of 29
SCOPE AND FOCUS OF THE PROJECT
Yetailed Condition Confirm Identify
Capacities &
Assessments D-
Technical Pee
ConfirmReview
SelectionDevelop Lifecyclem
Costs for
Cost and Phasing .
s� Alternatives
31
CENTRALSAN
MAJOR PROJECT DELIVERABLES
• Tech Memo 1 - Heat to Energy: Condition Assessment of
Steam, Energy and Aeration/Secondary Systems
• Tech Memo 2 - EI&C: Condition Assessment of Electrical &
Instrumentation Systems
• Tech Memo 3 - Nutrients: Design Criteria Development &
Improvements to Meet Current & Future Nutrient Regulatory
Requirements
• Tech Memo 4 - BCEs: Business Case Analyses for In-Kind
Replacement & Other Alternatives, including do nothing
• Tech Memo 5 -Water Exchange: Business Case Analysis for
Water Exchange Alternatives
• Tech Memo 6 - PDR: 10% Pre-Design Report for selected
alternative
16
December 20, 2018 Regular Board Meeting Agenda Packet- Page 151 of 168
Page 28 of 29
PROJECT SCHEDULE
ask NameStart Finish p79 p20 —1
J F M A M J J A S O N D J F M A M J J A S O N D J I F I M I A
Consultant Notice to Proceed 2/7119 717119
ASK 1-PROJECT MANAGEMENT 217179 313787
ASK2-CONDITION ASSESSMENT 314119 10110119 i
ASK 3-DEVELOPMENT OF DESIGN 411119 5114120
CRITERIA AND FEASIBLE ALTERNATIVES
O MEET CURRENT AND FUTURE
REGULATORY REQUIREMENTS
TASK 4-BUSINESS CASE EVALUATIONS 819119 1011YA i
FOR RECOMMENDATIONS
ASK5-BUSINESS CASE ANALYSIS FOR 218119 10.3fd
ATER EXCHANGE ALTERNATIVES
ASK 6-PREDESIGN REPORT 70174120 2!25!27
ASK 7-RESPON SES TO PEER REVIEW 7129119 .31.11
Technical Engineering Peer Review
`33
FORMATION OF PEER REVIEW PANEL IS BASED
ON THE FOLLOWING AREAS OF EXPERTISE
Technical Expertise:
• Steam System
• Secondary Process/Aeration System
• Electrical System
Business Case Evaluation Expertise:
• Business Case Evaluations/Alternatives
LLjec, Phasing Expertise:
roject phasing/packaging
41
17
December 20, 2018 Regular Board Meeting Agenda Packet- Page 152 of 168
Page 29 of 29
BOARD ACTIONS RECOMMENDED
Staff recommends the following:
• Authorize General Manager to execute a professional
engineering services agreement with HDR Inc. in an
amount not to exceed $2.59 Million for the condition
assessment and predesign of the Steam and Aeration
Blower Systems Renovations Project, District Project
7349; and
• Authorize the General Manager to execute an as-
needed agreement with Carollo Engineers Inc. in an
6aLmountnot to exceed $300,000 for peer review
.
`35
QUESTIONS?
18
December 20, 2018 Regular Board Meeting Agenda Packet- Page 153 of 168