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HomeMy WebLinkAbout03.b. (Handout) Revised Presentation (as presented at meeting) Item 3.b. (Attachment 7) Revised Presentation _ } PUMP STATION UPGRADES, PHASE 1 aA DISTRICT PROJECT 8436 Engineering and Operations Committee October 29, 2019 Jean-Marc Petit,Director of Engineering and Technical Services Edgar J.Lopez,Capital Projects Division Manager ee�m,a v eer v COLLECTION SYSTEM PUMP STATIONS (PS) UPGRADES Pe.-Hil L„w PHASED PROJECT IN TWO o � e PROJECTS: 6e�Xele 9D PHASE 1: MORAGA, ry..,lle ORINDA CROSSROADS, OM-d AND FLUSH KLEEN PS o R.mw. a PHASE 2: MARTINEZ, .m FAIRVIEW, o P.mp�asmo. AND MALTBY PS Treatrnem­1-rvxw cw.u'woe Fsiiiry ff1 vmarety Oxnetl wmpiop Smoon � c re GCGSp Punpinp S,alions bymmem Iseneremeinlmmaialm� w. na A ush' W muenwn for 3]9, y Q,� 1 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 i 3 PHASE 1 PUMP STATION CAPACITIES Current Flow Pump Motor Pump Station Min.-PDWF to Standby Power PWWF Two Diesel Engine Driven Wet Orinda Crossroads 0.45-1.82 24.77 MGD 3—150 HP(Elec.) Weather Pumps 22.0 MGD 2—1000 HP(Eng.) and 75-kW Generator for Building Two Diesel Engine 3—150 HP(Elec.) Driven Wet Moraga 0.71—2.41 18.58 MGD 2—1000 HP(Eng.) Weather Pumps 13.4 MGD and 75-kW Generator for Building Flush Kleen 0.015-0.68 MGD 1.47 MGD 2—15 HP(Elec.) 50-kW Generator MGD=Million Gallons per Day PDWF=Peak Dry Weather Flow PWWF=Peak Wet Weather Flow 4 2 PUMP STATION HISTORY OVERVIEW Pump Station Year Major Work Completed since Constructed E Original Construction 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 station.Components have been Flush Kleen 1950 1983 replaced in time or added for reliability(ex.generators in 1998) PROJECT DRIVERS ELECTRICAL, RELIABILITY AND RESILIENCY • Electrical: • Major electrical, instrumentation, and controls (EI&C) replacement and rehabilitation required • 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 critical 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 j 3 ORINDA CROSSROADS PUMP STATION ISSUES • Largest pump station for Central San • Receives flow from 7 other PS • Located in a very busy downtown ' commercial area in Orinda �1 • Limited property available for new equipment • 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) .5. • 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 1\' equipment issues(overheating)) • Piping corrosion issues j ORINDA CROSSROADS PUMP STATION r n: r� Al 8 4 VERY LIMITED SPACE AVAILABLE r • f 5 ORINDA CROSSROADS PS SCOPE OF WORK Orinda Crossroads PS needs the following work: • EI&C upgrades • �� • 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) / io r G '- 5 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) 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 • New grinder structure(s) "- • New dry pit submersible for dry weather pumps** M • 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) /►� y iz 6 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 Option 20-ye8r-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 O&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 O&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 of full 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 of flows with the Caterpillar engine due to limited turndown capabilities of diesel engine driven pumps • Major future upgrade project to replace existing Caterpillar engine with 2atl 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 O&M cost • Highest risk associated with construction sequencing and constraints • Requires relocation of radiator to non ideal location • Least preferred by O&M staff 13 BCE ALTERNATIVES AND OPTIONS EVALUATED FOR ORINDA CROSSROADS AND MORAGA PS . ®�agmn ,o•aprw m;,on °aq �,m;,o• .m a x.x ,wn ma:," Zmp. ..�,<.:°� am.= p.a,p= ,Mmv. „w r¢ s�xzw v¢ secou ¢Is1 ns xegaa _P- urpibr e.azx<a zaa mowsa P—) wsn4M lzwolzlspumce l. ■ weamerP—p ge nwrl lane axln>s par �n< v¢ scmq v[s ss.oxq NONE c­�� V1. pace e.o.nwu.a b.a.nw=aa Aewn..`n Is'p nany„ r¢ s/.ssm vcs 5e.rsm oclzl xaga.. bna Is. loll loll xtwaga lzl rwm b.o.zxm zo.a 1 xeboce vs rts sson•. xo WA zsoxw NONEa.v=w=o.a Al Wumtaory 151 pummar Ps ©,ba YE5 13stif-szxm No xlA .1A ./A WA ./A WA WA rv/A b.o.nw=a.1 sex/A 56.ssan vcs 5e.asan /s rcwpl weq.ce o mns r¢ Isa.s5m1511 Iss.vsmisll NEON c cerwm vco b.o.nmza.a IWwmprtnmM1 ¢I I4 Haase existing�s xw gerenwrs.mbapian wrn resgre me repacemena orwe newgeneraror insranea unaermb prase x prolenln me rururewnenmeocerpwarenyre tevenrualryregacea.iarai prolett........... sburmveasm auew Innarbn. Izl um aror lsao rcw ar moraeaa - mplcen prolett auamis option wai repgre meregacemenrar m Oso waumwaeaana ssoxrvwarocl aneary wea neranasranabvseneraro�ana me war weamerpumpan enelne. I>Irmicearro'nospaceon�sllwwrrinmulumn m'zw xwttneraro�n8�acerareareaary weawerp mpalpowrsl WnralaawrsVoremain� lal•oral proiett<wrin arrenr xnnuanerxoza ss.inauaes prase x proleu am eererrea rwure wsrs Isz.xm/narmp. Isl narr•e°orinaw<�ory weamerxnoww veakaweaswea<near n wnlvowfl�`u am eererrea twure wsrs lsz.pm/narmnl.same werau rural prgm<wrasoprlm t,aur more%are eererrea. 14 7 PUMP ALTERNATIVES EVALUATION AT ORINDA CROSSROADS AND MORAGA PS INCLUDE: REUSE AND REFURBISH EXISTING PUMPS VS. SUBMERSIBLE DRY PIT 0 Reuse of Existing Morris 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 FLUSH KLEEN PS SCOPE OF WORK Flush Kleen PS needs the following work: • Replace existing pumps, piping, �. and valves • New standby generator _ • EAC improvements =� • New dry weather pumps _ • Other miscellaneous improvements (structural, -s. architectural, heating, ventilation and air conditioning, etc.) y 16 r 8 ANTICIPATED SCHEDULE • Pre-qualifying general contractors and electrical subcontractors prior to advertising Construction Manager Selection • Public outreach ongoing with City and Town • 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) • Completed Tasks and Activities 17 PUMP STATION UPGRADES PROJECT PROJECT DESIGN, BID,AND CONSTRUCTION SCHEDULE µ^ms Under Preliminary Design F� Under Construction C dwu>nM111v+nHaW ConeMemPtiIF•tl vwq PI• IFS ww•�Halw aprr�ry ` 18 9 SUMMARY OF BIDS NO. BIDDER BID PRICE 1 Mountain Cascade, Inc. $24,292551 Livermore, California ' 2 C. Overaa &Co. $25,594000 Richmond, California ' 3 Kiewit Infrastructure West Co. $29,194000 Fairfield, California ' ENGINEER'S ESTIMATE: $24,000,000, INCLUDING ALL ADDITIVE BID ITEMS Pre-Qualified 9 GCs and 10 ESCs Eligible to submit a bid . f 19 BID & ESTIMATE REVIEW • Discuss bids with MCI and second lowest bidder Overaa. • VWHA estimate was $26 million before the bid. • Central San estimate did not include escalation. • This project will span multiple years (almost 3 years). • All critical and major equipment designed for and specified are included in MCI's bid. • Electrical and controls costs are higher. • Generators are more expensive due to high demand with PSPS. • Complex and high-risk project for contractors. • Very strict construction milestones, due to wet weather restrictions. • Overall, staff believes that the bid is the lowest costs and rebidding would not change the results. I zo r 10 MOUNTAIN CASCADE, INC (MCI) (GENERAL CONTRACTOR) Pre-Qualification Experience MCI Recent Experience • Five (5)similar projects with a ✓ Screen Pumping Plant minimum of$50M in contract . Natomas Mutual Water Company($18.8M) volume and at least one (1) ✓ Wastewater Pump Stations project must have a construction . County of SLO($9.2M) value of at least$15M since ✓ Pumping Plant and Reservoirs 2012 • EBMUD($9.5M) • Bonding capacity of at least ✓ $125M in capacity at time of pre- $25M qualifications • Safety and insurance ✓ Safety and insurance requirements requirements were met Note:The project manager was also prequalified with project size and similarity(wastewater, water, stormwater etc.) ` 21 CENTRAL SIERRA ELECTRIC (ELECTRICAL SUBCONTRACTOR) Pre-Qualification Experience Central Sierra Experience • Five (5) similar projects with a ✓ Wastewater Treatment Plant minimum of$12M in contract • City of Richmond($7.1M) volume and at least one (1) ✓ Disinfection Chemical Storage project must have a construction • Sacramento Regional SD($4.8M) value of at least$3M ✓ Water Treatment Plant • Donner PUD($2.8M) • Bonding capacity of at least ✓ $15M in capacity at time of pre- $6.5M qualifications • Safety and insurance ✓ Safety and insurance requirements requirements were met Note:The project manager was also prequalified with project size and similarity(wastewater, water, industrial construction, etc.) ` 22 11 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. _ y 23 TOTAL PROJECT COSTS REVIEW • Approximately $5.8 million difference from FY 2019-20 Budget, due to: • $3 Million higher in construction costs (including about $900K for escalation) • $1 Million for North Grinder Structure • $1.3 Million for resiliency for dry weather pump replacement (six new dry pit submersibles) • Construction management services outsourced and specialty inspection • $400,000 included in allowances • This Fiscal Year (FY) 2019-20 and FY 2020-21 will not need funding, however, FY 2021-23 has a budget shortfall. I 24 12 FINANCIAL IMPACT DP# Pro'ect Name To Date FY 2019-20 FY 20-21 FY 21-22 FY 22-23 Total Budget Budget Bud elBud et Budget Budget Pump Station Upgrades, $3,700,000 $4,600,000 $12.875'000 12,875,000 $5,833,180 $1,635,000$28,643,180 8436 Phase 1CudnBid 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 ccumulative Budget Carry Forward or $- $600,000 $3,475,000 $(3,091,820) $(5,847,820) Shortfall Future CIP Collection System Sewer $1,500,000 Adjustments 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 $ doustments 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. ` 25 SEWER CONSTRUCTION BUDGET COMMITMENTS AND CAPACITY UPDATED WITH THIS PROJECT $120 $120 --t $100 $100 1 1 I 1 $80 i 30.5; $80 $60 r $60 1 r 1 r r r �29.2j $40 t j 52.0 r 53.7 r r $40 61.7091 1 $20 r $20 $0 — — $0 19/20 20/21 21/22 22/23 Fiscal Year O Approved and Projected Budget per FY et•Committed already(contracted) r.J Remaining capacity with existing rales Additional capacity with planned increases —SSC funding capacity from Existing Rates' *Future years amounts may differ to the extent of reserve drawdowns.Additional analysis required. ` 26 13 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. j z 5. RECOMMENDATIONS j z8 14 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. f 29 QUESTIONS? 15