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Home My WebLink About21. Update on emergency situation re Lower Orinda Pumping Station (VFDs) Page 1 of 7 Item 21. k�*k CENTRAL SAN CONTRACENTRAL • February 20, 2020 TO: HONORABLE BOARD OF DIRECTORS FROM: EDGAR J. LOPEZ, CAPITAL PROJECTS DIVISION MANAGER REVIEWED BY: JEAN-MARC PETIT, DIRECTOR OF ENGINEERING AND TECHNICAL SERVICES ROGER S. BAILEY GENERAL MANAGER SUBJECT: RECEIVE UPDATE ONAND CONTINUE AUTHORIZATION FOR EMERGENCY DECLARED ON JANUARY 16, 2020 AUTHORIZING REPAIR OR REPLACEMENT OF THE VARIABLE FREQUENCY DRIVES (VFDS)AT THE LOWER ORI NDA PUMPING STATION;AND AUTHORIZE THE GENERAL MANAGER UNDER PUBLIC CONTRACT CODE 22050(B) TO CONTINUE TO REPAIR OR REPLACE THE VFDS IN ACCORDANCE WITH PUBLIC CONTRACT CODE 22050(C)(3) Attached is a presentation on the Lower Orinda Pumping Station Variable Frequency Drives Emergency Declaration Update. Strategic Plan Tie-In GOAL TWO: Strive to Meet Regulatory Requirements Strategy 1 - Strive to achieve 100%permit compliance in air, water, land, and other regulations, Strategy 2- Strive to minimize the number of sanitary sewer overflows GOAL 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 3- Protect District personnel and assets from threats and emergencies ATTACHMENTS: 1. Presentation February 20, 2020 Regular Board Meeting Agenda Packet- Page 155 of 161 Page 2 of 7 LOWER ORINDA PUMPING STATION (PS) VARIABLE FREQUENCY DRIVES EMERGENCY DECLARATION UPDATE Board Meeting February 20, 2020 Jean-Marc Petit Director of Engineering and Technical Services a Edgar J. Lopez Capital Projects Division Manager Al EMERGENCY DECLARATION SINCE LATE 2013 • Emergency Sludge Blending Tank: Declared: 05/20/14—end date: 7/3/14; Pre-stressed concrete tank failure - safety related • Orinda Miner Road: Declared: 3/12/17 (damage caused by winter storm)—7/6/17 (repairs completed); 11/15/18 - Announcement all funds reimbursed by the Federal Emergency Management Agency and California Governor's Office of Emergency Services • Primary Sedimentation Tanks Rail Repairs: Declared: 8/3/17, done under contract change order to the Primary Treatment Renovation, District Project (DP) 7285 • Electrical for Filter PS and Substation 40: Declared: 11/13/18, done under contract change order to the Filter Plant and Clearwell Improvements, DP 7365 •ft Lower Orinda PS Variable Frequency Drives (VFDs) Failure: Declared: 1/16/20—still open z CENTRALSAN 1 February 20, 2020 Regular Board Meeting Agenda Packet- Page 156 of 161 Page 3 of 7 BACKGROUND WHAT HAPPENED AT LOWER ORINDA P$ • Three VFDs for wet weather pumps (250-horsepower(hp) pumps 103-105) • One VFD failed on pump 105 in late winter, early 2019, and could not be repaired. Power locked out due to burned parts • Engineering was in the process of designing replacement VFD under Uniform Public Construction Cost Accounting Act with electrical consultant. New design resized VFD to 300-hp. • On January 16, 2020, a second VFD on pump 103 failed • Robicon Corporation (Robicon) parts are obsolete and no longer manufactured • Robicon agreed to sell its assets to Siemens Energy&Automation i6ha. June 2005 3 LOWER ORINDA P$ r■ CENTRALSAN 'd i ,• y J 4 2 February 20, 2020 Regular Board Meeting Agenda Packet- Page 157 of 161 Page 4 of 7 LOWER ORINDA PS FEATURES • Originally built in 1948—Major renovation in 2004 • Converted to all electric • Three 4900 gpm (7.05 MGD)250-hp wet weather pumps with VFD and bypass • Two 1900 gpm (2.74 MGD)75-hp dry weather pumps with VFD • Dry weather flow: 1.3 MGD • Wet weather flow: 7.5 MGD • Peak wet weather: 17.64 MGD • 850 kilowatt emergency diesel generator • Controls include a relay logic with float to operate pumps across the line upon VFD failure(hard-wired backup pump) gpm=gallons per minute MGD=millions of gallons per day 5 CONCERNS AND RISKS ASSOCIATED VFD FAILURES • Robicon VFDs have been failing more frequently. Central San spare parts inventory for these drives or third-party parts was very limited or are not available. • Staff has electric board refurbished by a third party. Parts were being repaired and waiting on more parts to be returned. • Similar failure recently happened at the San Ramon PS (also using Robicon VFD) and repaired by staff. • With two out of three VFDs out of service or unreliable, in such a short time, concerns of a systematic failure could possibly lead to the third VFD to fail, resulting in no variable controls for the pumps. • VFD bypass would prevent a sudden overflow condition while PS is unattended. 4 • These VFD failures even on a bypass mode would require 24-hour staffing by Operations. ` 6 3 February 20, 2020 Regular Board Meeting Agenda Packet- Page 158 of 161 Page 5 of 7 DECLARATION OF EMERGENCY ON JANUARY 16, 2020 • Pumping Station Superintendent Leo Gonzalez notified Engineering that a second VFD had failed on the wet weather pumps at Lower Orinda PS around 12:30 p.m. and rain was forecasted. • Within one hour, staff requested at the Board meeting at 1:30 p.m. to add an emergency declaration to the agenda to initiate repairs and/or replacement of the VFDs at the pumping station. • Wet weather pumps are required during the rainy season. Dry weather pumps do not have the pumping capacity. Peak wet weather requires use of wet weather pumps. CENTRALSAN ACTIONS SINCE EMERGENCY DECLARED • Identified and contracted with Fiore Industrial Electrical Services from Los Angeles to troubleshoot and repair the failed VFDs. These have since been repaired. However, there is no guarantee on reliability. • Finalized design of replacement VFDs. Selected 300-hp Eaton drives. • Issued a purchase order to Eaton Corporation to purchase three VFDs plus one spare. • Will replace and install the new drives under PS Equipment Replacement Project, DP 8442. • Requested quotes from three electrical contractors pre-qualified under the Pump Station Upgrades, Phase 1 project: • D.W. Nicholson Corporation • Telstar Instruments • Sierra Electric Il ' a CENTRALSAN 4 February 20, 2020 Regular Board Meeting Agenda Packet- Page 159 of 161 Page 6 of 7 COMPARISON OF DELIVERY METHODS EMERGENCY VS. TRADITIONAL PROJECT PHASE 2020 J F M A M J J A S O N D Design Phase Emergency Action Bid Phase 6 months Construction _ Traditional Design Phase Design/Bid/ Bid Phase — Construct Construction LEGEND PDesign Bid Activities Construction(Procurement) Construction (Installation) ` r 9 CENTRALSAN PROJECTED COSTS •$15,000 for VFD repairs, not including staff time •$200,000 for new VFDs (Approx. $50,000 each) •Costs to come: • Contractor installation of new VFDs • Staff and consultant time r 10 CENTRAL SAN 5 February 20, 2020 Regular Board Meeting Agenda Packet- Page 160 of 161 Page 7 of 7 QUESTIONS? CENTRALSAN 6 February 20, 2020 Regular Board Meeting Agenda Packet- Page 161 of 161