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03.b. Review draft Position Paper to award a construction contract in the amount of $24,292,551 to Mountain Cascade, Inc., the lowest responsive bidder for the Pump Station Upgrades, Phase 1, District Project 8436; include a bid alternative in the amount
Page 1 of 49 Item 3.b. CENTRAL SAN BOARD OF DIRECTORS POSITION PAPER DRAFT MEETING DATE: OCTOBER 29, 2019 SUBJECT: REVIEW DRAFT POSITION PAPER TO AWARD A CONSTRUCTION CONTRACT IN THE AMOUNT OF $24,292,551 TO MOUNTAIN CASCADE, INC., THE LOWEST RESPONSIVE BIDDER FOR THE PUMP STATION UPGRADES, PHASE 1, DISTRICT PROJECT 8436; INCLUDE A BID ALTERNATIVE IN THE AMOUNT OF $1,342,000; FIND THAT THE PROJECT IS EXEMPT FROM THE CALIFORNIA ENVIRONMENTAL QUALITYACT (CEQA); AND AUTHORIZE THE GENERAL MANAGER TO EXECUTE TWO PROFESSIONAL ENGINEERING SERVICES AGREEMENTS WITH: 1)V.W. HOUSEN AND ASSOCIATES I N AN AMOUNT NOT TO EXCEED $900,000 FOR ENGINEERING SUPPORT DURING CONSTRUCTION; AND 2) PSOMAS I N AN AMOUNT NOT TO EXCEED $1,800,000 FOR CONSTRUCTION MANAGEMENT SERVICES SUBMITTED BY: INITIATING DEPARTMENT: KEITH GELLERMAN, ASSOCIATE ENGINEER ENGINEERING AND TECHNICAL SERVICES- CAPITAL PROJECTS REVIEWED BY: SASHA MESTETSKY SENIOR ENGINEER EDGAR J. LOPEZ, CAPITAL PROJECTS DIVISION MANAGER JEAN-MARC PETIT, DIRECTOR OF ENGINEERING AND TECHNICAL SERVICES ISSUE On October 24, 2019, three bids were received for the construction of the Pump Station Upgrades, Phase 1, District Project 8436 (Project). The Board of Directors (Board) must award the contract or reject bids within 50 days of the bid opening. Authorization is required for the General Manager to execute the Contract Documents subject to submittal requirements; and to execute agreements with V.W. Housen and Associates (Engineer of Record) and Psomas (Construction Management). BACKGROUND In 2015, Central San staff initiated an evaluation of the Moraga and Orinda Crossroads Pump Stations (PS) at the request of Operations due to several deficiencies with the standby power engine driven systems, electrical and instrumentation concerns, and other equipment identified for replacement. The most impactful item identified was replacement of the 1,000-horsepower Waukesha diesel engines (circa 1959) at both stations. October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 10 of 90 Page 2 of 49 The 2017 Comprehensive Wastewater Master Plan identified additional electrical, mechanical, structural, and instrumentation work needed at Moraga and Orinda Crossroads, including similar renovation at Flush Kleen. Staff decided to package the three pump stations into one construction effort, which has been included in the current Capital Improvement Budget titled Pump Station Upgrades, Phase 1, District Project 8436 (Phase 1). I n May 2017, staff issued a formal Request for Proposals (RFP) advertised on PlanetBids and the Central San website to select a professional engineering consultant to provide design services for the project. The intended scope outlined in the RFP included design services and follow-up services during construction. Three proposals were received (Carollo Engineers, Inc., Stantec Consulting Services (MWH), and V.W. Housen and Associates (VWHA)). Staff evaluated the proposals, interviewed the consultant teams, and recommended VWHA as the best overall fit for the project. On July 20, 2017, the Board was informed of the planning and predesign effort for Phase 1 and the Phase 2 Martinez pump stations (Martinez, Fairview, and Maltby). Staff recommended evaluation of these pump stations for efficiency since similar investigation and condition assessments were needed. At that meeting, the Board authorized staff to hire VWHA to assist in the project development by providing condition assessments and technical support to allow staff to consider alternatives and ultimately recommend the best project approach. At the May 3, 2018 Board Meeting, staff presented the predesign findings and recommended final design of Phase 1, which included a detailed alternative analysis and business case evaluations (BCEs) conducted by the project team. At the meeting, the Board authorized staff to perform the final design with VWHA. Phase 2 would be initiated later due to land acquisition needed for the proposed work. Overall, the scope of work mainly consists of upgrading emergency generators, installing new electric driven wet weather pumps, major electrical upgrades, new grinders (Moraga only), and various piping, valves, and control upgrades needed for the pump stations. The following is a summary of the history, detailed scope of work, and the BCEs conducted for each pump station in the Phase 1 project: Moraga and Orinda Crossroads Pump Stations Moraga PS, originally installed in 1959, is located at 1790 School Street in Moraga, across from Hazelwood Court in a residential neighborhood. Orinda Crossroads PS is located at 10 Camino Pablo in Orinda, across from Brookwood Drive in downtown Theater Square. These stations were installed around the same time and are nearly identical in design and features. They have gone through upgrades, with the most recent renovation performed around 1998. The pump stations consist of three dry weather electric pumps and two wet weather diesel engine driven pumps (Waukesha and Caterpillar engines). During the predesign, staff determined that an "all-electric" option (Option 2 described below)warranted consideration prior to committing to replacement of the Waukesha engine, generator installation, and other related improvements. The predesign included BCEs that provide alternatives at both stations to handle an emergency situation due to the loss of PG&E grid power. The alternatives and options include the following: • Option 1 - Keep engine driven pumps for wet weather pumps (i.e., keeping the Caterpillar engine at each PS with new controls and installing a new engine to replace the Waukesha engine.); • Option 2 -All-Electric pumps. This included evaluating the use of 480 V (volt) versus 4160 V as the wet weather pumps would be equipped with larger electric motors (650 horsepower); • Option 3 - Electric Hybrid. The Electric Hybrid option implements the "All-Electric" Option 2 described above by installing one electric wet weather pump and deferring replacement of the 1998 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 11 of 90 Page 3 of 49 Caterpillar diesel engines with the second electric wet weather motors and other electrical equipment to a future project; • Option 4 - Building a new pump station at another location for Orinda Crossroads. This alternative was not pursued due to the lack of available sites and the high cost associated with relocating the gravity sewers and infrastructure; • Option 5 -Abandoning the Orinda Crossroads PS and converting the system to gravity flow. Four sub-alternatives were identified and evaluated under this option.Although these options were feasible from an engineering standpoint, they were all too costly as compared to the renovation alternatives proposed in the other options described above. During the July 25, 2019 Board Meeting, another option (Option 6)was presented by the Board to staff. This option was a variation to Option 3, which includes replacing the Waukesha engine with electric driven pumps and variable frequency drive (VFD), keeping the Caterpillar engines (updating the controls), and replacing the standby 75-kilowatt generator in kind. Option 6 would have a generator sized only to power lighting and other auxiliary loads but would not be able to power any of the pumps.Attachment 1 provides full details of the options and BCEs. Staff determined that Option 2 (All-Electric) is the preferred alternative at both stations for multiple reasons: • It provides the ability to operate all five pumps at each pump station under electrical power, using VFDs to match the flow and pumping capacity, and improves pumping transitions and low flow operations during PG&E outages. • It provides resiliency during a PG&E's Public Safety Power Shutoff (PSPS) event. In October 2019, the Moraga, Orinda Crossroads, and Flush Kleen Pump Stations were impacted by a PSPS and Central San continued operation at these locations using backup power and large engines/wet weather pumps at low dry weather flows. Option 2 is the best alternative for Central San during these events, which most likely will be more frequent in the future. • Adding the latest Tier 4 standby generator will minimizes future requirements associated with escalating Bay Area Air Quality Management District regulations for diesel engines. • It standardizes the Moraga and Orinda pump stations. The conversion to all electric pumping was implemented successfully at the Lower Orinda Pump Station in 2003. This approach is standard operating practice for all other major Central San pump stations. Additional evaluations and BCEs were performed to address pump station resiliency, which includes seismic, external flooding, internal flooding due to equipment or piping failure, and surge and corrosion protection. I n order to address internal flooding, staff recommends the replacement of the dry weather pumps from vertical centrifugal dry pumps to submersible dry pit pumps. Recognizing the fact that the existing dry weather pumps were replaced in the early 2000's and the capacities are adequate, staff has included this recommended improvement as a bid alternative. The scope of work for these stations also includes, but is not limited to, new generators sized to pump build-out peak wet weather flows; new PG&E service and motor control centers, including configuration of breakers to allow for operator servicing, and implementing Arc Flash safety requirements; replacing surge tanks; and adding grinders at Moraga PS to address the ongoing maintenance caused by wipes and other debris. October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 12 of 90 Page 4 of 49 Flush Kleen Pump Station Flush Kleen Pump Station, originally built in 1950, is one of Central San's oldest pump stations. Certain electrical, instrumentation and controls (EI&C) equipment are obsolete and replacement parts cannot be obtained from manufacturers. The EI&C assessment recommended replacing the standby power generator, automatic transfer switch, electrical service, and power distribution. Staff recommends installing two new dry pit submersible constant speed pumps. The new pumps will allow build-out peak wet weather flows to be pumped through a single force main and for larger solids to be passed at low flows. Dry pit submersible pumps will provide increased resiliency at the station. It is recommended to replace piping and valves located in the drywell. General Contractors and Electrical Subcontractors Pre-Qualifications Based on the project complexity, staff issued a formal Request for Statements of Pre-Qualifications of General Contractors (GCs) and Electrical Subcontractors (ESs)on July 15, 2019. Pre-qualifications included assessment of past performance and safety, experience, and financial status. Central San received interest from ten GCs and ten ESs; nine GCs and ten ESs were approved and invited to bid the project. Construction Management Selection Staff issued a formal Request for Proposal to provide third-party construction management (CM), that would include construction management, inspection, special inspection, and start-up services. Central San received proposals from five CM firms: Kennedy Jenks; Psomas (previously Covello Group);Anchor CM; Consolidated CM, and 4Leaf, Inc. VW HA was not allowed to submit as it would be a conflict of interest to perform construction management on their own design.After reviewing the proposals and conducting interviews of the top-ranking firms, staff selected Psomas for this project. Bidding The Engineer's estimate for construction of Phase 1 was $24 million, including the additive bid items.A project location map is shown in Attachment 2. VW HA and staff prepared the plans and specifications for the project. This project was advertised on August 26 and September 3, 2019. Three sealed bids ranging from $24,292,551 to $29,194,000 were received and publicly opened on October 24, 2019. The Engineering Department conducted a technical and commercial review of the bids and determined that Mountain Cascade, Inc. is the lowest responsive and responsible bidder.A summary of bids received is shown in Attachment 3. Staff recommends including the $1,342,000 additive bid item submitted by Mountain Cascade, Inc. for the six dry pit submersible pumps at the Moraga and Orinda Crossroads Pump Stations, but not to include the $985,000 alternative bid item for the South Grinder Structure at the Moraga PS. Staff will present its findings of the low-bid pricing compared to the Engineer's estimate at the Committee meeting. Capital Projects staff will provide oversight of the CM, Engineer of Record, and contractor during construction of the project. Operations will staff at least one operator at the stations during the project to coordinate shutdowns and provide any support needed to run the station. Public outreach with the Town of Moraga and City of Orinda, along with public relations with the impacted businesses and residents, will be coordinated through Central San's Communication Services group. Psomas is planned to be the day-to-day contact with the contractor and provide construction management services that includes services stated above in addition to other CM duties, such as documenting the project, reviewing schedules, and safety oversight. VMHA will be retained since they are the Engineer of Record and will assist with submittal reviews, contractor requests for information, and design clarifications. October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 13 of 90 Page 5 of 49 C EE A: Staff has concluded that this project is exempt from CEQA under Central San's CEQA Guidelines Section 15301, since it involves minor alterations to existing public facilities involving no expansion of use, and CEQA Guidelines Section 15302, since it involves replacement of existing public facilities at the same location and with the same purpose.Any capacity increases are for non-growth inducing, wet weather purposes. Approval of this project will establish the Board's independent finding that this project is exempt from CEQA. ALTERNATIVES/CONSIDERATIONS The Board could consider the following alternatives or provide other direction: 1. The project included two additive bid items: o Construction of a grinder structure and equipment at the south gravity feed to the Moraga Pump Station, which costs $985,000. Staff does not recommend including this bid alternative at this time. • Upgrade the dry weather pumps to dry pit submersible pumps to add resiliency from internal flooding at both stations (Moraga and Orinda Crossroads) in the amount of$1,342,000. Staff recommends including this bid alternative as part of this project to address resiliency concerns. The Board could elect to add or delete these additive items to the construction contract. 2. Staff's approach of supplementing labor with consultants, such as the Psomas CM agreement, could be rejected by the Board. Capital Projects is not currently staffed at a level to support to support this construction project.Additional staff, up to three persons, would have to be considered to perform construction management, general inspection, and resident engineering. Specialty inspection would need to be outsourced since staff does not have the qualifications to perform specialty work. 3. Reject all bids, which is not recommended. This project will address the deficient and aging infrastructure at the pump stations and provide long-term reliability and operational performance of the mechanical and electrical systems. FINANCIAL IMPACTS The total estimated project cost is $34,491,000, including planning, predesign, final design, staff, construction contract, a standard five-percent contingency, and other project costs detailed in Attachment 4. Phase 1 was included in the Fiscal Year(FY)2019-20 Budget on page 153 with an estimated budget of $27.85 million in 2019 dollars. This project will span multiple fiscal years and does not include escalation of future years (amounting to $28.6 million), which is accounted for in the District rate model.Although there is adequate funding for the project through FY 2020-21, there is a shortfall of approximately$5.8 million in the current Ten-Year Capital Improvement Plan. These funds will be supplemented from the FY 2021-23 Collection System Program under sewer renovation projects and future contingency as shown in Attachment 5, which also shows the current construction commitments in the Capital Program. For FY 2021-22, staff had increased the funding in the program for sewer renovation. This change will keep sewer renovations funded at the same level as currently performed. COMMUNITY OUTREACH Central San has held multiple meetings with both the Town of Moraga and the City of Orinda to answer any questions or concerns about the project. In addition, staff held an open house at the Moraga Pump Station on October 17, 2019, where residents had the opportunity to learn or ask questions about the October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 14 of 90 Page 6 of 49 project. Additional notifications will be provided to all impacted residents and businesses after the award of the project and before construction. COMMITTEE RECOMMENDATION The Engineering and Operations Committee reviewed this project at its meeting on October 29, 2019, and recommended RECOMMENDED BOARD ACTION Staff recommends the following: 1. Find that the project is exempt from CEQA; 2. Award a construction contract in the amount of $24,292,551 to Mountain Cascade, Inc., the lowest responsive and responsible bidder for the Pump Station Upgrades, Phase 1, District Project 8436; 3. Include a bid alternative to upgrade the Moraga and Orinda Crossroads Pump Stations to dry pit submersible pumps in the amount of $1,342,000; 4. Authorize the General Manager to execute the Contract Documents subject to submittal requirements; 5. Authorize the General Manager to execute an agreement with V.W. Housen and Associates in an amount not to exceed $900,000 for engineering services during construction; and 6. Authorize the General Manager to execute an agreement with Psomas in an amount not to exceed $1,800,000 for construction management services. Strategic Plan re-In GOAL TWO: Strive to Meet Regulatory Requirements Strategy 2- Strive to minimize the number of sanitary sewer overflows, Strategy 3- Comply with all federal, state, and local regulations related to District administration 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- Reduce reliance on non-renewable energy ATTACHMENTS: 1. Business Case Evaluations and Table 2. Project Location Map 3. Summary of Bids 4. Post Bid/Preconstuction Estimate 5. Phase 1 Construction Funding Tables 6. Presentation October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 15 of 90 Page 7 of 49 Attachment 1 Pump Station Upgrades, Phase 1, District Project 8436 Business Case Evaluations The Preliminary Design Report, completed in February 2018, includes a business case evaluation (BCE) that includes the following alternatives at both stations to handle backup power in case of loss of electrical grid power currently provided by PG&E. The alternatives and options evaluated in the BCE include the following options: Option 1) Keep engine driven pumps for wet weather backup power (this option replaces the Waukesha engine with a new engine for the wet weather pumps and upgrades the controls for the existing Caterpillar engine); Option 2) All-Electric (remove both engines and provide electric motors on all wet weather pumps. Provide a standby power generator large enough (800-900 KW) to power the entire station - both dry and wet weather pumps). The team evaluated using of 480 V versus 4160 V, as the wet weather pumps would be equipped with larger electric motors (650 HP); and Option 3) Electric Hybrid. The Electric Hybrid option implements the "All-Electric" Option 2 described above by installing one electric wet weather pump under the initial project but defers the replacement of the 20-year-old Caterpillar diesel engine/pump with the second electric wet weather pump to a future project. Under this option a new generator (350-400 KW) would be provided to power the dry weather pumps but not the new electric driven wet weather pumps. It should be noted that two additional options were evaluated for the Orinda Crossroads Pump Station (PS). One of these additional options: Option 4) included relocating the pump station to another location since the existing site is constrained. This alternative was abandoned due to the lack of available potential sites nearby and the cost that would be associated with relocating the gravity sewers and infrastructures to another location. Option 5) evaluated abandoning the Orinda Crossroads PS and converting it to a gravity flow. Three sub-alternatives to gravity flow from Orinda Crossroads were identified and evaluated. Although these options were feasible from an engineering standpoint, they were all too costly as compared to the renovation alternatives proposed in Options 1, 2 and 3 above. During the July 25, 2019 Board Meeting, another option (Option 6) was presented by the Board to staff. This option was a variation to Option 3, which includes replacing the Waukesha engine with electric driven pumps and variable frequency drive (VFD), keeping the Caterpillar engines (updating the controls), and replacing the standby 75- kilowatt generator in kind. Option 6 would have a generator sized for lighting and other auxiliary loads but would not be able to power any of the pumps. October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 16 of 90 Page 8 of 49 Staff determined that Option 2 (All-Electric) is the preferred option at both stations for multiple reasons: • It provides the ability to operate the pump station under electrical power, and using VFDs to match the flow, and pumping capacity and it improves pumping transitions and low flow operations. • It improves the ability to operate the pump station in low flow condition with large capacity pumps. • Adding a latest approved Tier 4 large single standby generator will minimizes future requirements associated with escalating Bay Area Quality Management District regulations for diesel engines. • It eliminates the engines which are only coupled with the wet weather pumps. • It eliminates additional foreseeable wet weather pumping future upgrades. • It standardizes the pump station. The conversion to all electric pumping was implemented successfully at the Lower Orinda Pump Station in 2003. • During recent implementation by PG&E of a Public Safety Power Shutoff (PSPS) event in mid-October 2019, the Moraga, Orinda Crossroads, and the Flush Kleen Pump Stations were impacted by this event, and Central San operated using the backup power and engines at these and other locations. The recommended alternative under Option 2 is the preferred alternative that best fits Central San needs to respond to these events which may be more frequent in the foreseeable future. The following table represents the BCE, including the new Option 6 evaluated: October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 17 of 90 Page 9 of 49 Pump Station Upgrades, Phase 1, District Project 8436 Business Case Evaluations Table mmOrinda Crossroads PS Standby Power Generators Firm Pumping Capacity (MGD) (2) • Description Applicability Estimated Applicability Estimated Size of New Powers PS Powers Wet Powers New Standby Wet Weather Wet Weather Normal Under Pumps Available under of Option of Option Construction of Option Construction Standby Lighting Weather Dry to Power All Pump 1 Pump 2 Operation Emergency Emergency Power Operating Cost Cost GEN Pump(s) Weather PS Electrical Power Condition (1St Qtr. (1st Qtr. Pumps Needs a. Orinda Operation 2018$) 2018$) b. Moraga a. Orinda b. Moraga Keep YES $ 7.12 M YES $ 8.10 M 250 KW OC YES YES YES Keep Replace a. 0.45 to Both Wet Weather Pumps on Engines (3) (1 pump = Caterpillar Waukesha 22.3 engines 300 KW PDWF) with a new b. 0.71 to (Two (2) pumps at each PS) Moraga Engine 14.4 + One Dry Weather Pump (generator) (One (1) pump at each PS) All Electric YES $ 8.00 M YES $ 9.02 M 750 KW OC YES YES YES YES Replace Replace a. 0.45 to All Pumps Dry and Wet Weather 650 KW Caterpillar Waukesha 22.3 (5) pumps at each PS on standby Moraga with electric with electric a. 0.45 to b. 0.71 to generator motor and motor and 22.3 14.4 VFD VFD Electric- YES $ 8.66 M (4) YES $ 9.75 M (4) 750 KW OC YES YES YES YES Keep Replace b. 0.71 to a. 0.45 to Three Dry weather pumps & One Hybrid (2) Caterpillar Waukesha 14.4 22.3 Wet weather pump on standby 650 KW with electric b. 0.71 to generator and Moraga (2) motor and 14.4 One Wet Weather on engine VFD Relocate YES $ 30 M + NO N/A 750 KW YES YES YES YES New pump New pump a. 0.45 to All Pumps Dry and Wet Weather PS with electric with electric 22.3 (5) pumps at PS on standby motor and motor and b. 0.71 to generator VFD VFD 14.4 Abandon YES $39M -$72M NO N/A N/A N/A N/A N/A N/A N/A N/A a. 0.45 to N/A PS and 22.3 convert to b. 0.71 to Gravity 14.4 Minimize YES $ 8.66 M (5) YES $ 9.75 M (5) 75 KW (1) YES YES Keep Replace a. 0.45 to Only one Wet Weather Pump Option 3 (1 pump = Caterpillar Waukesha 22.3 (1 pump at each PS) PDWF) but with electric b. 0.71 to no backup motor and 14.4 VFD Notes: (1) Reuse existing 75 KW generators. This option will require the replacement of the new generator installed under this Phase 1 project in the future when the Caterpillar engine is eventually replaced. Total project cost is same as Option 3 but increased due to inflation. (2) Limited to no space on site for installation of large generator with Caterpillar radiator to remain. Smaller generator(300 KW at Moraga and 250 KW at OC for PDWF = 1 dry weather pump) can be installed under Phase 1 project but this option will require the replacement of the smaller generator installed in the future when the Caterpillar engine is eventually replaced, increasing total overall cost. Under this option (300 KW at Moraga and 250 KW at OC)one dry weather on standby generator and one wet weather pump on engine. (3) Limited to no space on site for installation of 250 KW generator to operate one dry weather pump (PDWFs)with radiators to remain. (4)Total project cost in current 1 st Quarter 2018 $s. Includes Phase 1 project and deferred future costs ($1.1 M/station). (5)Total project cost in current 1st Quarter 2018 $s. Includes Phase 1 project and deferred future costs ($1.7M/station). Same overall total project cost as Option 3, but more $s are deferred. (6) Range of flow = PDWF Peak Dry Weather flow (PDWF)to PWWF = 10-yr design peak wet weather flow. October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 18 of 90 fi�� `fir ���, i,��' � � •, • %•�� ��! ��'�i` rJa'��il��� ��r;n■ OF owl Nunn.r 'A WM2 LUSH KLEEN PS-1i WN oil L Project AreaIVA Pump Station Upgrades, Phase 1 Attachment i 1 ACDENTMLSAN District Project 8436 2 CENTRAL CONTRA COSTA SANITARY DISTRICT Project Location • ••- . 1 . •- •' &memo •- •. '.•- • 0 •1 Page 11 of 49 ATTACHMENT 3 PUMP STATION UPGRADES, PHASE 1 DISTRICT PROJECT 8436 SUMMARY OF BIDS PROJECT NO.: 8436 NO. OF ADDENDA: 4 DATE/TIME: OCTOBER 24, 2019/2:00 PM PROJECT NAME: PUMP STATION UPGRADES, PHASE 1 PROJECT MANAGER: KEITH GELLERMAN PROJECT LOCATION: ORINDA AND MORAGA, CALIFORNIA ENGINEER'S ESTIMATE: $24,000,000, INCLUDING ALL ADDITIVE BID ITEMS NO. BIDDER BID PRICE 1 Mountain Cascade, Inc. $24,292,551 Livermore, California 2 C. Overaa & Co. $25,594,000 Richmond, California 3 Kiewit Infrastructure West Co. $29,194,000 Fairfield, California BIDS OPENED BY /s/Katie Young DATE: October 24, 2019 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 20 of 90 Page 12 of 49 ATTACHMENT 4 PUMP STATION UPGRADES, PHASE 1 DISTRICT PROJECT 8436 POST-BID/PRECONSTRUCTION ESTIMATE % Of Item Description Amounts Construction No. Cost 1. CONSTRUCTION a. Construction Contract $24,292,551 b. Alternative 131 —South Grinder at Moraga Only* $0 c.Alternative B2—Dry Pit Submersible Pumps $1,342,000 d. 5% Contract contingency $1,281,449 e. Permits (CalTrans, Orinda, Moraga, BAAQMD) $50,000 SUBTOTAL- CONSTRUCTION COST $26,966,000 100% 2. CONSTRUCTION MANAGEMENT a. District Forces - Project management $600,000 - Public Relations/Right-of-Way $50,000 - Operations $75,000 b. Consultants - Construction Management/Inspection (Psomas) $1,800,000 - ESDC (VWHA) $900,000 - Material Testing/Specialty Inspection $300,000 SUBTOTAL-CONSTRUCTION MANAGEMENT $3,725,000 14% 3. PREBID EXPENDITURES a. Engineering (Planning, design, staff and consultants) $3,800,000 SUBTOTAL- PREBID EXPENDITURES $3,800,000 14% 4. TOTAL ESTIMATED PROJECT COST $34,491,000 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 21 of 90 Attachment 5 Pump Station Upgrades, Phase 1, District Project 8436 Phase 1 Construction Funding Tables DP# Project Name To Date FY 2019-20 FY 20-21 FY 21-22 FY 22-23 Total Budget Budget Budget Budget Budget Budget Current Budget (*) 8436 Pump Station Upgrades, $ 3,700,000 $ 4,600,000 $ 12,875,000 $ 5,833,180 $ 1,635,000 $ 28,643,180 Phase 1 Budget based on Bid Results and Revised $ 3,700,000 $ 4,000,000 $ 10,000,000 $ 12,400,000 $ 4,391,000 $ 34,491,000 Cash Flow Variance $ - $ 600,000 $ 2,875,000 $ (6,566,820) $ (2,756,000) $ (5,847,820) Accumulative Budget Carry Forward or $ - $ 600,000 $ 3,475,000 $ (3,091,820) $ (5,847,820) (Shortfall) Future CIP 8451 Collection System Sewer $ 1,500,000 Adjustments Renovation Phase 1 TBD Collection System Sewer $ 2,756,000 Renovation Phase 2 Future CIP Contingency TBD or Sewer Construction $ 1,591,820 Fund Total Future $ _ $ _ $ - $ 3,091,820 $ 2,756,000 $ - Adjustments Revised Accumulative Budget Carry Forward $ - $ 600,000 $ 3,475,000 $ - $ - $ or Shortfall * Budget has been adjusted to reflect future escalation of 3% per year, which is included in the rate model. Page 1 of 2 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 22 of 90 Sewer Construction Budget Construction Commitments Table Sewer Construction Budget, Commitments and Capacity in millions 5120 e $120 $100 $100 the ' ;dea a � � , � $so be $s0 te $6�J'� $60 0 3.2 $40 4. $20 42. 5. 45. $20 $0 - $0 Fiscal Year 18/19 19/20 20/21 21/22 22/23 CEMMS Approved and Projected Budget per FY rX' JAdditional contractual cap acitywith approved rate adjustments I— Remaining contractual cap acitywith existing rates Committed already(contracted) Sewer Construction funding capacity from Existing Rate s * Future years amounts may differ to the extent of reserve drawdowns and planned borrowing. Page 2of2 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 23 of 90 Page 15 of 49 Attachment 6 h 1� PUMP STATION UPGRADES, PHASE 1 DISTRICT PROJECT 8436 Engineering and Operations Committee October 29, 2019 77 Jean-Marc Petit, Director of Engineering and Technical Services Edgar J.Lopez,Capital Projects Division Manager fs Keith Gellerman,Associate Engineer 4 Presentation Agenda Project Background and Drivers tirmpSe.igen - ,�m o' Project Scope Project Biding and . Organization Project Schedule, Budget anj Bid Results Recommendations I 1 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 24 of 90 Page 16 of 49 1 . PROJECT BACKGROUND AND DRIVERS 13 ° o COLLECTION SYSTEM PUMP STATIONS (PS) 8 �"ncdrd anl, UPGRADES Pl—t Hill PHASED PROJECT IN TWO o � e PROJECTS: 6e�kele 9D onnda _ PHASE 1: MORAGA, ryan.,lle ORINDA CROSSROADS, AND FLUSH KLEEN PS Oakland ow".mwn a PHASE 2: MARTINEZ, .mDJ 2 4FAIRVIEW, o Pwmp�dsmoon AND MALTBY PS �rrexnem Pka Land HHW�CeIe'�'Non Fsiliry ff1 Pmarety Oxnetl Pumpirp 5000n � c re GCGSp Punpinp S,alions mmem Isenernmeinmimaialmm wa d A Wdq W muenwn for& d a� � ;'3oorea �ra � mi "I. �pma�serewe=nnry � 4 2 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 25 of 90 Page 17 of 49 MAY 2017 -THREE PROPOSALS RECEIVED Lead Consultant _= Subconsultant Carollo Engineers, JDH Corrosion Consultants, Inc. (Corrosion) Consuning bervicM, Lee and Ro (Electrical) Inc. (MWH) • V&A(Corrosion) Housen and Associates HDR, Inc. (Corrosion) • ArcSine Engineering (Electrical) Northwest Hydraulic Consultants (Surge Analysis) Selected VWHA Design Services for Pump Station Formal RFP Issued—included pre-design and - Upgrades final design.Support services to be included during construction based on Construction award. ' s PROJECT BACKGROUND Moraga and Orinda Crossroads Pump Stations projects identified in Fiscal Year 2016-17 Capital Improvement Budget Confirmed in 2017 Comprehensive Wastewater Master Plan — Collection Systems. Scope increased based on condition assessments of electrical, controls, and piping systems 3 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 26 of 90 Page 18 of 49 PUMP STATION UPGRADES, PHASE 1 DISTRICT PROJECT 8436 PROGRESSION TIMELINE July 11,2017 E&O Requesting and July 20,2017 Board Recommendation to Authorized April 25,2018 E&O and Award Construction Agreement with May 3,2018 Board Authorized Contract VWHA for Amendment with VWHA for Final October 29,2019 Preliminary Design Design of Phase 1 Project,DP 8436 E&O of Project,DP 8436 2017 2018 2019 2020 February 2018 VWHA Submitted July 9,2019 E&O Preliminary Design, July 25,2019 Board: including 30%design Provided a Project Update to and Business Case the Board and Board Evaluation Report Maintained 5%Contract Retention for Phase 1 Sh stir,I�— Z4V 17 PUMP STATION UPGRADES PROJECT PRELIMINARY DESIGN REPORT OVERVIEW-TABLE OF CONTENTS Draft Preliminary Design Report Executive Summary Introduction Ids Reliability and Redundancy Cntem DESIGN SERVICES r, Facilities l-f FOR PUMP Martinez Pump Station �• '�'=° STATION Fairview Pump Station i"'- oxsrocr Pfojc t 3435 UPGRADES Malthy Pump Station praR Pre!lminary Design Report Flush-Kleen Pump Station Review Meeting Concord Main(South)Metering Stabban February 2018 .w��.,:.r•.__-._ F��..:.•:a���.� Maraga Pump Station Onnda Crossroads Pump Station Project Implementation Strategy Project Design and Construction Schedule I'8 4 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 27 of 90 Page 19 of 49 PHASE 1 PUMP STATION CAPACITIES Current Flow Firm Capacity Pump Motor Pump Station Min.to PWWF rgest pump —VITAPATAI ylv"y Standby Power t of service) Two Diesel Engine Driven Wet Orinda Crossroads 0.45-22.0 MGD 24.77 MGD 3—150 HP Weather Pumps 2—1000 HP and 75-kW Generator for Building Two Diesel Engine Driven Wet Moraga 0.71-13.4 MGD 18.58 MGD 3—150 HP Weather Pumps 2—1000 HP and 75-kW Generator for Building Flush Kleen 0.015-0.68 MGD 1.47 MGD 2—15 HP 50-kW Generator MGD-Million Gallons per Day PWWF=Peak Wet Weather Flow _ I 9 PUMP STATION HISTORY OVERVIEW CompletedPump Station Year Major Work Constructed M1 . . Replacement of dry weather pumps Orinda 1959 1998 and associated electrical,one diesel Crossroads wet weather engine,surge tank Replacement of dry weather pumps Moraga 1959 1998 and associated electrical,one diesel wet weather engine,surge tank Modified to act as a standard dry pit Flush Kleen 1950 1983 station.Components have been replaced in time or added for reliability(ex.generators in 1998) ' to 5 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 28 of 90 Page 20 of 49 PROJECT DRIVERS AGING ASSETS, RELIABILITY AND SUSTAINABILITY • Electrical: • Major electrical, instrumentation, and controls (EI&C) replacement or rehabilitation at the pump stations • Implement recommendations from the 2015 Arc Flash Study • Need to replace and upgrade the emergency power systems • Improve readiness to respond to PG&E's Public Safety Power Shutoff(PSPS)events (new driver) • Asset Rehabilitation: • Remedy deficiencies of Asset Conditions Technical Memorandum prepared under Comprehensive Wastewater Master Plan • Replace deteriorating piping, gates, and valves • Provide long-term corrosion protection • Resiliency: • Provide resiliency from flooding (internal and external) • Long-term reliable wet weather pumping concerns 11 ORINDA CROSSROADS PUMP STATION ISSUES • Largest pump station for Central San, located in a very busy downtown commercial area in Orinda and limited ?I property available for new equipment • Major concerns: • Diesel engines on wet weather pumps are aging. Limited availability of OEM replacement parts on Waukesha engine(—60 years of age)and engine control panels using DOS operating system(over 20 years of age) • Wet weather pump condition (Need rebuild) • Challenging operations during power outage during dry weather conditions,existing 1000- HP diesel engines used to pump low flows • No emergency power for dry weather pumps • Outdated EAC needs rehabilitation(ex. variable frequency drives(VFDs),existing equipment issues(overheating)) • Piping corrosion issues �s ' 12 6 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 29 of 90 • , CROSSROADS • STATION Tail r:la rr• ThPal - Y �5 1 All CIO Es \ Go le Page 22 of 49 MORAGA PUMP STATION • Major pump station: Second largest PS for Central San, located in residential ' neighborhood near a school and creek • Major concerns: • Diesel engines on wet weather pumps are aging. Limited availability _of OEM replacement parts on Waukesha engine (—60 years of age)and engine control panels . `�'•. using DOS operating system (over 20 years of age) • Wet weather pump condition (Rebuild) No emergency power for dry Challenging operations during power weather pumps • outage during dry weather Installation of mechanized grinders conditions, existing 1000-HP diesel (currently manual cleaning) engines used to pump low flows • Outdated EI&C needs rehabilitation (ex.VFDs) ';15 BUSINESS CASE EVALUATION AT CENTRAL SAN The following tasks are performed when preparing a Business Case Evaluation (BCE): 1. Evaluate specific project needs and drivers 2. Conduct an in-depth evaluation of existing asset condition assessment and determination of remaining life 3. Evaluate whether to keep, maintain the existing assets, replace in kind, and/or replace with new technology 4. Conduct pilot testing of preferred technology when appropriate to validate design criteria and risk, if applicable 5. Evaluate current and possible future regulatory drivers that would impact the project and identify solutions 6. Preliminary investigation as needed (geotechnical, survey, permitting, environmental, etc.) 7. Prepare design alternatives based on prior information 8. Prepare capital expenditure for each alternative 9. Evaluate operations and maintenance (O&M)for each alternative 10. Prepare pros and cons for each alternative 11. Prepare 20-year net present value(life cycle cost analysis)for each alternative 12. Present BCE to Executive Review Committee 116, 8 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 31 of 90 Page 23 of 49 RINDA CROSSROADS AND MORAGA PS ALTERNATIVES DISADVANTAGES Lowest current project construction • Uncertainty with continued escalating Bay Area Air Quality Management cost District(BAAQMD)requirements using engines Defers cost of replacing the existing • Unknown future requirements to replace the Caterpillar engine at a later date .• 20-year-old Caterpillar engine to a • Continued specialized O&M associated with the engines later date • Continued difficulty with pumping range of flows due to limited turndown Lowest risk with construction capabilities of diesel engine driven pumps especially during low flow condition sequencing and constraints • Major future upgrade project to replace existing Caterpillar engine • High 0&M cost • Not preferred by O&M staff Reliably pump entire range of flows • Highest current project construction cost from minimum to PWWF • Risk associated with construction sequencing and constraints Eliminates uncertainty of continued Optionescalating BAAQMD requirements Eliminates specialized O&M associated with the engines Replaces all wet weather equipment and avoids future major upgrades Lowest 0&M cost Preferred option of O&M staff More reliable to respond to PG&E PSPS using new larger generators Moves toward implementation of All- • Highest total overall construction cost when including future upgrades required Electric option while deferring cost to for implementation offull All-Electric option a future date • Uncertainty with continued escalating BAAQMD requirements �' • Continued specialized O&M for the Caterpillar engine • Continued difficulty of pumping range offlows with the Caterpillar engine due to limited turndown capabilities of diesel engine driven pumps • Major future upgrade project to replace existing Caterpillar engine with 2xd all- electric pump,install yet another new generator,and electrical modifications • Increased station complexity with both a diesel engine driven wet weather pump and an electric driven wet weather pump • High 0&M cost • Highest risk associated with construction sequencing and constraints • Requires relocation of radiatorto non ideal location • Least preferred by O&M staff BCE ALTERNATIVES AND OPTIONS EVALUATED FOR ORINDA CROSSROADS AND MORAGA PS 11,1111111111 11,1111x -Al., ON.6� st Mxw mxaxp xmp, E•mvx xmpx pxmpx P. a m xx a Ex ,ubxe,5 o m�a, SA. wm M a(aI ns ns H.gare Mrea E�o� rtoa�epo rs�m ol.borr �ar�u�bpvmr>at sa.mM rrs ss.ozM ns rrs ra weware a.o.asteaz.� 022.3All I. o,r „ ..at Mreaw bxm . x Y.x bb,xroxa. Isotlom �aM r[s 58.86Ml1l 11 $9.75M(4) 75l 011 111, era Mana lxl erpma e.o.�xm xo.a vFo anabyp 1 Relorrte Ps rt5 51Me No x/A )w xw MEMO m vFo ;0.411111 .xAl .ltto xe.a All ry wexMra`5 ©ow r¢ 58x.411. NO NIA WA NIA rv/A x/A N/A rv/A N/A b.o.ixm xo.a He WA apnoH r¢ IISE lsl r¢ Ss.xsMlsl —O) ENER-P m pla xvNo b.a.xtwv.a weeteerpump �x rympyatnm Ixl xe Izl um torlso - mp�arcgammentaf im 11 KW atMo-agaana zso Hw at ocl oneary weaeneron atanabr Henermor ana mews weatnerpumpone Ul um pa�powH:lw rsrorereaia. lalm w5�i8 ao ro nalh.x naa ' Isl.o a ro am aeierrea mwre ronel5x./M/meo�.same werau ental pre�enamtaaoqoo a,ben more 5aare aekrrea. 18 181 rva - ve�voWf�lett 9 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 32 of 90 Page 24 of 49 OPTION 6: ABANDON ORINDA CROSSROADS PS FOUR ALTERNATIVES EVALUATED Option 1:Gravity to Lower Orinda with new FMs Option 2:Gravity to Lower Orinda and Tunnel -4' +11 _7 Option M1 v Option 3:Gravity to Lower Orinda with new FMs Option 4:New 36"Diameter Tunnel I 19 MORAGA AND ORINDA CROSSROADS PS wiia EVALUATED ENGINE VS. ALL-ELECTRIC OPTIONS Recommending All-Electric: • New PG&E service • VFDs for wet weather pumps • New VFDs on dry weather ..v pumps • 800-900 kW standby generators • Reliability • Redundancy • Resiliency 20 10 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 33 of 90 Page 25 of 49 PUMP ALTERNATIVES EVALUATION AT ORINDA CROSSROADS AND MORAGA PS INCLUDE: REUSE AND REFURBISH EXISTING PUMPS VS. SUBMERSIBLE DRY PIT ®Reuse of Existing Morris _ _ d-4111111111 Pump Casings with Smaller Impellers and New 700-HP Horizontal Electric Motors Least Cost Alternative ® Install New Dry Pit Submersible Electric Pumps Provides Increased Resiliency Moraga Pump Station 3D Visualization Bid Dry Pit Submersible for Dry Weather Pumps 2. PROJECT SCOPE �;zz 11 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 34 of 90 Page 26 of 49 ORINDA CROSSROADS PS SCOPE OF WORK Orinda Crossroads PS needs the following work: • EI&C upgrades "�= t • �� • New standby generator sized to operate entire station during wet weather(largest pump) • Wet weather pumps: • New rotating assembly -� • Conversion to electric driven pumps with VFDs • New dry submersible dry pit weather pumps (*) • New surge tank • New PG&E service (* Bid Alternative B-2 Recommended) I 23 MORAGA PS SCOPE OF WORK Moraga PS needs the following work: • EI&C upgrades • New standby generator sized to operate station in wet weather • Wet weather pumps: • New rotating assembly r • Conversion to electric driven _ pumps with VFDs r: „ • New grinder structure(s)* F • New dry pit submersible for dry weather pumps** • New surge tank • New PG&E service * Bid Alternative B-1 for new south grinder box _ ** Bid Alternative B-2 dry pit submersible pumps(Recommended) '24 12 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 35 of 90 Page 27 of 49 FLUSH KLEEN PS SCOPE OF WORK Flush Kleen PS needs the following work: • Replace existing pumps, piping, �. and valves • New standby generator • EI&C improvements • New dry weather pumps • Other miscellaneous improvements (structural, architectural, heating, ventilation and air conditioning, etc.) pw 25 3. PROJECT BIDDING AND ORGANIZATION M 13 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 36 of 90 Page 28 of 49 GENERAL CONTRACTORS AND ELECTRICAL SUBCONTRACTORS PRE-QUALIFICATIONS • Due to the Project complexity, Central San conducted a formal Request for Statements of Pre-Qualifications of General Contractors (GCs) and Electrical Subcontractors (ESs) issued July 15, 2019. • Pre-Qualification included past performance and safety, experience, and financial status. Central San received interest from ten GCs and ten ESs. Nine GCs and ten ESs were approved and invited to bid. Project publicly posted for other subcontractors and vendors. pw = .. AdW 21 CONSTRUCTION MANAGEMENT SERVICES Construction Management Selection • Staff issued a formal Request for Proposals to provide third-party construction management (CM), including inspection, special inspection, and start-up and construction management. Central San received proposals from five CM firms: Kennedy Jenks; Psomas (Covello Group); Anchor CM; Consolidated CM; and 4Leaf, Inc. • In accordance with Code 1090, VWHA was not allowed to submit as it would be a conflict of interest to perform construction management on their own design. • After reviewing the proposals and conducting interviews of the top-ranking firms, staff selected Psomas for this project. 28 14 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 37 of 90 Page 29 of 49 PROJECT ORGANIZATIONAL CHART CENTRAL SAN PROJECT MANAGER Coordinate with Central San staff andall parties • Manage project budgets Approve progress payments, invoices,change orders(COs),etc. • Major decision maker � I CENTRAL SAN CONSTRUCTION MANAGEMENT DESIGN ENGINEERS O&M STAFF (PSOMAS) Services During • Construction Construction management • Review and Daily Inspection (VWHA) implement CONTRACTOR --- Document tracking -- Review submittals shutdowns (submittals,Request for Answer RFIs • Operating Information(RFI),COs,DTRs) Start up support station,provide Safety oversight Design clarifications support Point of contact with Review Final O&M Contractor manuals and asset • Progress meetings information CENTRAL SAN PUBLIC Review payments Produce electronic OUTREACH Manage and review project's record drawings schedule • City of Orinda Coordinate shutdowns • Town of Moraga Specialty inspection • Homeowner outreach and (Electrical or others) resolutions Commissioning • Commercial businesses Manage project closeout '.29 4. PROJECT SCHEDULE, BUDGET AND BID RESULTS '.30 !. 15 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 38 of 90 Page 30 of 49 ANTICIPATED SCHEDULE • Pre-qualifying general contractors and electrical subcontractors prior to advertising (Completed) • Public outreach ongoing with City (Completed) • Advertise —August 26 and September 3, 2019 • Bid Opening — October 24, 2019 • Engineering & Operations Committee — October 29, 2019 • Board Award — November 2019 • Notice to Proceed — by December 2019 • Complete construction by Spring 2022 (Majority of work during summer of 2020 and 2021) I 31 PUMP STATION UPGRADES PROJECT PROJECT DESIGN, BID,AND CONSTRUCTION SCHEDULE Under Preliminary Design my = Under Construction C dwu>nM111v+nHaW %MIMI. ConeMemPti�IFiwf vwq Pn�lF�vbk.�wmr aprr�ry 16 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 39 of 90 Page 31 of 49 SUMMARY OF BIDS NO. BIDDER BID PRICE 1 Mountain Cascade, Inc. $24292,551 Livermore, California ' 2 C. Overaa&Co. $25,594,000 Richmond, California 3 Kiewit Infrastructure West Co. $29,194,000 Fairfield, California ENGINEER'S ESTIMATE: $24,000,000, INCLUDING ALL ADDITIVE BID ITEMS 4 a. I 33 E TOTAL ESTIMATED PROJECT COST Of Item Description Amounts Construction No. Cost 1. CONSTRUCTION a.Construction Contract $24,292,551 b.Alternative B1—South Grinder at Moraga Only` $0 c. Alternative B2—Dry Pit Submersible Pumps $1,342,000 d.5%Contract contingency $1,281,449 e. Permits(CalTrans,Orinda,Moraga,BAAQMD) $50,000 SUBTOTAL-CONSTRUCTION COST $26,966,000 100% 2. CONSTRUCTION MANAGEMENT a.District Forces -Project management $600,000 -Public Relations/Right-of-Way $50,000 -Operations $75,000 b.Consultants -Construction Management/inspection(Psomas) $1,800,000 -ESDC(VWHA) $900,000 -Material Testing/Specialty Inspection $300,000 SUBTOTAL-CONSTRUCTION MANAGEMENT $3,725,000 13.8 3. PREBID EXPENDITURES a.Engineering(Planning,design,staff and consultants) $3.800.000 SUBTOTAL-PREBID EXPENDITURES $3.800.000 14.1 4. TOTAL ESTIMATED PROJECT COST $34,491,000 'This item costs$985,000 and staff is not recommending to include the work to the Contract. 1 iiiiiiiimmw 17 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 40 of 90 Page 32 of 49 FINANCIAL IMPACT DP# Project Name To Date FY 2019-20 FY 20-21 FY 21-22 FY 22-23 Total Budget Budget Budget Budget Budget Budget Pump Station Upgrades, $3,700,000 $4,600,000 $12,87 5,000 $5,833,180 $1,635,000$28,643,180 Current Bud et 8436 Phase 1 Budget based on Bid Results and Revised $3,700,000 $4,000,000 $10,000,000 $12,400,000 $4,391,000$34,491,000 Cash Flow Variance $- $600,000 $2,875,000 $(6,566,820) $(2,756,000)$(5,847,820 Accumulative Budget Carry Forward or $- $600,000 $3,475,000 $(3,091,820) $(5,847,820) Shortfall Future CIP Collection System Sewer $1,500,000 djustments 8451 Renovation Phase 1 Collection System Sewer TBD Renovation Phase 2 $2,756,000 Future CIP Contingency or Sewer Construction $1,591,820 TBD Fund Total Future $- $- $ $3,091,820 $2,756,000 $ Adjustments Revised Accumulative Budget Carry Forward $- $600,000 $3,475,000 $ $ $ or Shortfall - *Budget has been adjusted to reflect future escalation of 3%per year,which is included in the rate model. a - I 3a5 SEWER CONSTRUCTION BUDGET, COMMITMENTS AND CAPACITY (UPDATED) Sewer Construction Budget,Commitments and Capacity$in millions $120 $120 $100 $100 date ' $80 10 1 V / $80 $60 $40 32r $40 ¢,r $20 42.r 5.r r45. $20 $0 — - $0 Fiscal Year 18/19 19/20 20/21 21/22 22/23 m Approved and pr i-1 eudget per Fy Additionalconvamalcapacitywithapprovedrateadjust— C lRemainingcontramalcapacitywithcxistingrates e�Commimdalready(contacted) Sewer C—ouN-funding opacity from Rxisdng Rates' 'Future years amounK may differ to the extent of reserve drawdowns and planned borrowing. Li 18 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 41 of 90 Page 33 of 49 ALTERNATIVES/CONSIDERATIONS: The Board could consider the following alternatives or provide other direction: • Include or delete any of the two additive bid items: South grinder Moraga Pump Station, which costs $985,000 (recommend to delete); and Dry pit submersible upgrade at both stations (Moraga and Orinda Crossroads) in the amount of$1,342,000 (Recommend to include) • Revisit current staffing levels in Capital Projects instead of outsourcing construction management (Not recommended). • Reject all bids, which is not recommended. zy 11 5. RECOMMENDATIONS '.38 19 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 42 of 90 Page 34 of 49 BOARD ACTIONS AND STAFF RECOMMENDATIONS Staff recommends the following: 1. Find that the Project is exempt from CEQA; 2. Award a construction contract in the amount of$24,292,551 for the construction of the Pump Station Upgrades, Phase 1, DP 8436, to Mountain Cascade Inc., the lowest responsive bidder; 3. Include the bid alternate to upgrade the Moraga and Orinda Crossroads stations to dry pit submersible pumps in the amount of $1,342,000; 4. Authorize the General Manager to execute Contract Documents subject to submittal requirements; 5. Authorize the General Manager to amend an existing professional services agreement to increase the cost ceiling by$900,000 with V.W. Housen and Associates for engineering support services; and 6. Authorize the General Manager to execute a professional services agreement with Psomas for$1,800,000 for construction management services. QUESTIONS? �;40 R' 20 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 43 of 90 Page 35 of 49 _ e � r 1 ADDITIONAL INFORMATION (NOT TO BE PRESENTED) 4 PUMP STATIONS SERVING CENTRAL SAN 0 0 &u anon - Ch'de Concord O xweh Indus[rlal Hu[hanin Fetrvllw O south h[elt6y Mar[dnez a RWI rreaT,—W Plan[: hlprig San Roman Orroda 0 Crossroads Q er o 41lnda Acacia Slelpy Hollow Wagner Flush Ranch _ lee 21 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 44 of 90 Page 36 of 49 PREVIOUS UPGRADES - 1999 Central Contra Costa Sanitary district Gon[ Costa caunly e�� �C�Iifamfa • Dry Weather Pumps �MypLt)MP30F3 ----,� • Surge Tanks FAD�9gCaterpillar Engine-1997 ms F-C4ud.Cf DISTRICT MoirCT No.5237 --- —i= rhRAGA RMG =. vw[M•Acxvaa[[oAea $7.3 M Investment rurPIM•TAVOLA _ x9mWATION PXWECT r Will I 43 DIESEL ENGINES AT MORAGA AND ORINDA CROSSROADS PUMP STATION • Original installation for Waukesha • New Caterpillar in 1997 =�= • Difficult to obtain parts and - perform repairs ' • Direct connection to wet - weather high capacity t . - x 44 22 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 45 of 90 Page 37 of 49 ENGINE RUNNING HOURS Orinda Cross Roads PS w Caterpillar: 1,200 hrs. Caterpillar: 1,004 hrs. Waukesha: 5,524 hrs. Waukesha: 2,832 hrs. *As of July 25,2019 i a 1 i 23 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 46 of 90 -J 1 � o ! • ,dam Page 39 of 49 OUTDATED CONTROL PANEL FOR ENGINES Issues: 1. Operates on Microsoft Dos OS 2. 20 yr. old control panel technology 3. Parts not available from OEM 4. Currently purchasing used parts on eBay r i i i i ' 49 PROPOSING TO REPLACE DRY WEATHER PUMPS WITH DRY PIT SUBMERSIBLE FOR INCREASED RESILIENCY a 9' Issues: _l_ • 1. Pumps Replaced 20 years ago 2. Not connected to standby power 3. Past Experience with Major Internal Flood Event 4 v 1 L M r-�lT 1 '.so 25 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 48 of 90 Page 40 of 49 POTENTIAL FUTURE RISK IRIEpop.'T -- PUMP C00"' L— opserv0"r GpNTRA e 1"11%JFailwre Releases Sewa9 -- -- r� � a PaN�she7 L40 s�SaN•dsY•6ehN•�'1111996-_- ___ ��� -_a�Pu]dR ypnSnffued� ti y � onm:da� and san pyo Dam Rrvvu, v,g tam Onnda_'fief�Nlo]he red pyiot an rn'et{lon diSalCd ra-�" P 6uSs[oPe]+,Pa'] �flM�cd[a the Ses�T•vV �� "' rain, -an n.�' n'd1CT U1sirS[t x-Age, t'85 tasTa ratan soorm ds�ro;aa Fa6LQ[]edti,}a�rn]t mue3 [.�ss�Cnnv ��sap➢� 151t'an i6 Ck� ���r�ypytel'f` - -roes ' ]CA�] '� []'m'•- �vt81f'Ae�]SS•dt�' ---- ------ -- ----- -- C.rnaulItmeGrsta6arm8°n -- - -- _ Vy - _ i aifnio Tern Ht.kx TWo'�A 1i'a m]4me 24i dwpr.rw.umu. n,�,m-h� .n.wwmr.u.' – "`" —�.wr•" o:..e�rpr.�n nvaw•,um....s ore.tirar.• Lj �+1 a]fxenyC3W .pYlm,ue nnsea pe mrtRF mffse rin eney� u� �Nec.� un[rv�i]h]uu f�1-'x[pnYixv� •'4 Kam a���vnrf?•. Wim+ +w Ls. ��A*na�v+eeyeY�eq.s i. '.52 26 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 49 of 90 Page 41 of 49 From me Lower c.nmoa rump tepalred the ekc6cal system. -and –-__ lag 5ratbn Into the Crossroads one. and ding top ma Every• a ` Station.Before cmva arrived make re on were called diesel help one•---camestg top manage on the scene,the water In the make repairs to the withmei tame tagerher and used sallun's pump room had risen enPnes and w help wEth the the rexpenhe[eaccampush H)a depth Of about 15 feel pumpvo]ute�angeatt what CWD Manager John Crews Goan pumpmgout the The pump volute blowout could mon called a"mlrade,' waterwhhin 45 minutes thanks not have been anticipated "There was a professional and to the quick actkn of CSOD Apparently the enormous pres focused efrort to get the pump crews and their new emergency sure of a'water hammer"event station back on line as soon as _ response equipment. blew ole 314-Inch thlrk cast possible,"Bald john."i was Two of the six elecLfc movers that pump wastewater out of � f Al F+x POD MaRwr thunk ARM+Rd PUMOV searlo4 Superv6y"Hunch Zdpr erambv rhEfra-rumd prmp 'L WfUN Al VW ottxv cmisrpid$AMk&fg Slalrae 0674 .. woks is�x was Slkld nOp,CR mtlf 7 cvmr{q fOf[h Ejvft vs Siy a lwafer hammer'mYW flap die w4fle"blew Iff J'd•l7Cd CdSl 11YM deA)'arlalY. t2 Rlfdl SdR 2rS XA)rked dS d frn7Jlyd fCAM rhf09A lffe RUN to"W they RWW alallo back 4;rMr--ArJarygnr,you carp see how mese pumps 7nvr. _, vRd2r 40+nN1 oyl°raliwJ. 20— NENIIIIlIIIW 12. EMERGENCY SITUATIONS REOUlj3l Q BOARD ACTION a. FEBRUARY 12, 19c ;FECT REPAIRS I[Q TH kRY 12 IL Mr. Dolan, General Manager-Chief Engineer, stated that he declared an emergency on Thursday evening, February 12, 1998, when a significant pump failure at the Orinda Crossroads Pumping Station caused the loss of all pumping capabilities resulting in a one million gallon spill onto Camino Pablo in Orincle. Mr.Dolan introduced Mr.James Kelly, Plant Operations Division Manager, and Mr. John Pear(, Plant Maintenance Division Manager,who gave a full report to the Board on the incident. Mr.Kelly stated that on Thursday,February 12, 1998,at 7;01 p.m.the first alarm from the Orinda Crossroads Pumping Station was received. The on-call Pumping Stations Operator was deployed immediately and arrived at the site at approximately 7.30 p.m. The Pumping Stations Operator found the upper stage volute of the 3,000 gpm electricof pump had broken in half. This failure mode allowed the lower stage pump to continue to pump dilute raw sewage,which filled the dry well to a 10-foot depth. Upon arrival,the Pumping Stations Operator immediately turned off the pump. At this time,both diesel motor driven pumps were under three feet of water,and the motors for both lower stage ' 5a 27 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 50 of 90 Page 42 of 49 SFWQCB IMPACT FROM 1998 OVERFLOW • Per failure analysis from Montgomery Watson, cause by "mechanical failure of a pump that could not have been reasonably anticipated or prevented by operator intervention or that could be attributed to operator negligence". • Of the 1 M gallon, approximately 300,000 gallons of overflow was considered sewage, balance was rainwater. • Station was back on line in 10 hours, repaired in 31 hours. • Central San made no claim against insurance (Self Insurance Risk was $1 million, total loss costs probably did not reach that attachment point). • Although there was a declared disaster in effect, Central San did not file an application for FEMA/state reimbursements for this event(did for other incidents around that time). • Regional Board assessed an Administrative Civil Liability (ACL)fine of$55,700 (.54/gal). • Central San 'paid'the fine by doing an environmental enhancement project. INSTALL MOTORIZED GRINDERS AT MORAGA PS r� Issues: 1. Manual bar racks at Moraga 2. Frequent plugging of pumps 3. Decrease reliability of pumping station due to increase possibility of plugging pumps 28 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 51 of 90 Page 43 of 49 CORROSION PROTECTION • Central San PS have experienced corrosion- related failures Pump Discharge • Project approach included: Piping at Martinez • Field investigations and ultrasonic thickness IN testing Wet Weather Pump • Determination of cause of coating and Suction Piping swo and Orinda Crossroadsrds corrosion failures • Evaluation of existing cathodic protection systems and installation of temporary systems to determine current demand Recommendations and cost for repair/replacement Recommendations to prevent future pop corrosion and provide long-term protection I 57 FLOOD PROTECTION/ SEA LEVEL RISE -- Pump Flooding Potential al Site $ea Level Ri.e Station (Protected Water Su Race Elevation NAVD , FEMA FEMA Note. +30 +50 +100 Flootl years years years Hazard Zane Fluah- X Outside of FEMA flood hazard zone - - - Kleen Moraga X Adjacent to 100yaar fwd phin(1%prebrioddyaf fleodingevery _- year,Zane AE=High n.kunder National Flood lnwrance - Progmm) Orinda AH Within 100-ywrfloodplain(1%pmbobilityoflwdingevgyeer, - - - Cmamoad. with shallow flooding(ponding)wflh depths of 1-3 het of depth) I 58 29 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 52 of 90 Page 44 of 49 USE OF 3D FOR PRE-DESIGN 3D advantages: • Visualize improvements • Optimize tight spaces/clash detection • Convey information to stakeholders 3D Visualization of Wet _ Weather,Dry Pit Submersible Pumps at Moraga Pump Station I 59 CONVERSION FROM ENGINE TO ELECTRIC DRIVEN PUMPS HAS MANY ADVANTAGES • Eliminates special O&M associated with engine-driven pumps • Concerns about parts availability: only used parts available for Waukesha engine and control panels from online source (e.g.; eBay) • Improves pumping transitions during low flow operations • BAAQMD regulations for diesel engines including future stricter engine replacement requirements and limitations for exercising the engines • Similar layout and design to Lower Orinda PS which was for to All Electric Pumps ',eo 30 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 53 of 90 Page 45 of 49 UNDER "ALL ELECTRIC" OPTION, STANDBY POWER IS REQUIRED FOR ONE WET WEATHER PUMP + AUXILIARY LOADS Orinda X Rd Moraga Preferred Standby 's Generator Location Potential Generator Locations Potential Alternate ^ Locations Smaller than Anticipated Wet Weather Pump Horsepower Could Result in Smaller Generators that May Fit in Existing Radiator/Generator Enclosures as compared to 1000 HP Engines ' 61 OAnda Cmssroads Pump Stattan-pump and System Curves(Fxl og) n.l�a % i 3 0 Ym Nxa IYm �x�p 1Yw lLlav lXm �SnT..pY4M m r...p Pw!-��r Yr1..�c7i0R�l.xl�w�1�Rl Fn�F41 ^�iW� rc��um Mr[yivalfexr �iM�pFloxfwre -- ywq�I�n,wfknc giwlcxvzin•�niww�ni - +�moW imv.r• wcel +^wl�'�i —4��w sye�m��..5�00 — Nb4+.^�m•sw�l 31 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 54 of 90 Page 46 of 49 "ALL ELECTRIC•• OPTION AT ORINDA CROSSROADS PS Hydraulic Analysis was Performed Using Updated Master Plan Buildout PWWFs in Pursuit of Optimal System Orinda Crossroads Pump Station-Pump and System Curves Orinda Crossroads Buildout PWWFs 390 - T 18"FM(C=110) Current Master Plan Buildout(10-yr event) Morris Madel NC 30a16e16 I ,'.'et Weather Ad} 301 FM(¢=1101 250 - Pumps(Full SPeed1 - - 2 Dry Weather Adz Met r Adj 22.3 MGD Pumps IFull Speed) Pump jFull Spee a V _ 1 Wet Wea r1WjCurrentReliable Capacity PDmp182.5% ed) p - 18"and 30" • , FM IC=110 �..E. E 3 Dry Weather Adj Reliable Buildout P`WWF Capacity of _ Pumps(Full Speed)_ 22.3 lMGD requires ell Madel - n 8NNT-VC180a - c ' HP 0 10 20 30 40 50 1 Dry Weather Adj m d Pi.W Wet Weather Pumps Pump(Full Speed) S&D loss Curves ( g) Ijjj 63 M oraga Pump Statlon-Pump and System Curves�Eftistfng) Ir iC0 rw PT .wrlMl snMwl� -_- �HQwaywr �fk^w lwlrwrnrwwnc lafFf3 Mva•`arw lfwewl ---f4M�a WlVlse•pn ry 4 kR+.�sae.l d k^+^u r+••w.:I s.fvRprn teal —4Atbr4rrnrIM+SYW —kasurY w.0 lust wu wMrtar•fail — rwYnwp tr�nwx] .a.i ' 64 32 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 55 of 90 Page 47 of 49 "ALL ELECTRIC" OPTION AT MORAGA PS Hydraulic Analysis was Performed Using Updated Master Plan Buildout PWWFs in Pursuit of Optimal System Moraga Pump Station-Pump and System Curves a� 16"FM(C=1101 Fr _ (10-yr event) Marris Model NC 10x16.16 27"FM(C=110) 2. Wet Weather Adj Purtp(F Speed) 16"and 2T-- FMs(C-110) 14.41 MGD ,r Zoo 2 Wet Weather Adj �'• Pumps(Full Spee s ---- 2Dry weather AddReliableCapacity 'E 150 Pumps..kFu11 Speed) o _ 3 Dry Weather Adj21 MGD M 1m ti. o` Pumps(Full speed) _ r E E E _d �S Wet Weather Adj 50 __ Reliable Buildout PVVWF Capacity of Pump(fl9 Speed) ^ Corn II Model o —N14.41 MGD requires 3 BNN7-VC180B p 1 , i.� • 1 HP 0 10 20 30 40 30 1 Dry Weather Adj Flow(rngd) Wet Weather Pumps Pump{Full5peed) ADLosa Curves SURGE PROTECTION • Provided for dry weather electric pumps • Diesel engines have significant inertia to prevent rapid shutdown, which reduces surge potential • Under the "All Electric" option, the force mains , require additional surge , 3 protection s Ilk ar xm ' 66 33 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 56 of 90 Page 48 of 49 MORAGA AND ORINDA CROSSROADS PS "ALL-ELECTRIC" OPTION EVALUATION • The final "All-Electric" option Evaluation Technical Memorandum was prepared • "All-Electric" option (Option 2) is recommended for implementation based on the following advantages: • Replaces all wet weather pumping equipment at the stations and eliminates additional foreseeable future upgrade projects • Minimizing future requirements associated with escalating BAAQMD regulations for diesel engines including future unknown engine replacement requirements and limitations for exercising the engines Eliminates special O&M associated with engine-driven pumps • Improves pumping transitions and low flow operations Avoids obtaining additional land at the Orinda Crossroads site '.67 MORAGA AND ORINDA CROSSROADS PS "ALL-ELECTRIC" OPTION EVALUATION, CONTINUED • Replace the existing motor control centers and dry weather pumps with dry pit submersible pumps for added resiliency • Use Alternative 2A—All-Electric option (Reuse Morris Pumps) due to the disadvantages associated with installing/removing wet weather dry pit submersible pumps from the building and to match the equipment proposed for use at the Orinda Crossroads PS • Instrumentation Upgrades • Implement updated standards in certain instrumentation areas, for up-to-date and consistent installations aii '.68 34 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 57 of 90 Page 49 of 49 END OF ADDITIONAL MATERIAL I 69 35 October 29, 2019 Special EOPS Committee Meeting Agenda Packet- Page 58 of 90