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Home My WebLink About04.d. Receive update on Steam and Aeration Blower Systems Renovation, DP 7349 Page 1 of 14 Item 4.d. CENTRAL SAN January 19, 2021 TO: ENGINEERING AND OPERATIONS COMMITTEE FROM: NITIN GOEL, SENIOR ENGINEER REVIEWED BY: DANEA GEMMELL, PLANNING AND DEVELOPMENT DIVISION MANAGER EDGAR J. LOPEZ, CAPITAL PROJECTS DIVISION MANAGER JEAN-MARC PETIT, DIRECTOR OF ENGINEERING AND TECHNICAL SERVICES ROGER S. BAILEY, GENERAL MANAGER SUBJECT: RECEIVE UPDATE ON STEAM AND AERATION BLOWER SYSTEMS RENOVATION, DISTRICT PROJECT 7349 Staff will present an update on the Steam and Aeration Systems Renovations Project. Strategic Plan Tie-In GOAL TWO: Environmental Stewardship Strategy 1—Achieve 100% compliance in all regulations, Strategy 2—Anticipate and prepare for potential regulatory changes, Strategy 4- Reduce reliance on non-renewable energy GOAL FIVE:Infrastructure Reliability Strategy 1—Manage assets optimally to prolong their useful life, Strategy 2—Execute long-term capital renewal and replacement program, Strategy 3—Protect personnel and assets from threats and emergencies GOAL SIX: Innovation and Optimization Strategy 2—Improve and modernize operations through technology and efficiency measures ATTACHMENTS: 1. Presentation January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 45 of 66 Page 2 of 14 STEAM AND AERATION BLOWER SYSTEMS RENOVATION (DISTRICT PROJECT 7349) UPDATE Engineering and Operations Committee January 19, 2021 Jean-Marc Petit, Director of Engineering and Technical Services Danea Gemmell, Planning and Development Division Manager Edgar Lopez, Capital Projects Division Manager Nitin Goel, Senior Engineer CENTRALSAN AGENDA w • Overview of Steam and Aeration Blower Systems Renovation Project (Steam Project) • Steam Project Status Update l • Business Case Evaluation (BCEs) Overview and Preliminary List of BCEs/ Alternatives - _ _I•r.. I to IL aL L. _ •� uJ3mli��Rli3Lf� . CENTRALSAN January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 46 of 66 1 Page 3 of 14 STEAM SYSTEM IS CRITICAL FOR THE SECONDARY PROCESS Furnace Exhaust7, ' Waste Wet Induced erraft Boilers Scrubber Fan Scrubber Water to Primary Steam Piping Effluent Steam Pre-Aeration Turbine Cake Multiple Blowers Hearth Landfill gas Furnaces Electric; (MHF) Standby Boiler to Plant St m A/N Tanks Power Potable water Feeds: Facility 0. Feed MHF Boilers Mixed Liquor Cogen Boiler Cogan Channels Water Aux.Boilers Electricity Meter Turbine from Grid Turbine Fin.I Effluent Ash � Channel Handling ♦♦ ►` System Natural Gas ♦♦♦ �♦♦ Future Needs (Nutrient Removal) ' 3 CENTRALSAN CENTRAL SAN SECONDARY TREATMENT PROCESSES f. IR r. ��p��rr��Jt�R }may., s (� i�rL11•F �rn�� __.a I�d�Pll.'1r�.n r, -r,.�l��■ all CENTRALSAN January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 47 of 66 2 Page 4 of 14 D STEAM &AERATION BLOWER SYSTEMS RENOVATIONS PROJECT ELEMENT' 1 i • 1 _ Steam Generation a �'•'w_ Boiler Feed Water i Steam& ,¢ Condensate Piping e I 16� r s ,n r Optimize Selector New Diffusers&Piping - ^1 &Aeration Tank Rehab _ Dedicated Aerated Grit Re-Use Blower Building i s * m Blowers for New Blowers? 5 SUB 52 Electrical Upgrades 0 SECONDARY TREATMENT/ELECTRICAL CONSIDERATIONS SUB 82 Electrical Upgrades ♦' - kFp4. Mixed Liquor y Hydraulic Splitter Box — Rehab Clarifiers ! SUB 33&34 _ and RAS/WAS Electrical Upgrades u ; s 6 CENTRALSAN January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 48 of 66 3 Page 5 of 14 PROJECT ELEMENTS TO BE EVALUATED t , SUB 82 Contaminated Soil Electrical Upgrades Future Nutrient Relocation Water Exchange Future Clarifiers? Removal Tanks �- Steam Generation i O New Boiler Feed Water .666. Blower • ❑O Building? _ r Steam& Condensate Piping Mixed Liquor Rehab Clarifiers Hydraulic I'� Add Splitter Box Generator �+ - CEPT SUB 33&34 Electrical Upgrades New Diffusers&Piping Optimize Selector &Aeration Tank Rehab Dedicated Aerated Grit re-Use Blower Building t primary Expansion Blowers r New Blowers? SUB 52 Electrical Upgrades 7 CENTRALSAN SCOPE AND FOCUS OF THE PROJECT Detailed Assessments Capacities and Alternatives Design Criteria W- nWd � Develop Lifecycle Confirm - .-r Costs for Cost and Phasing Selection of Best Alternatives / 8 January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 49 of 66 4 Page 6 of 14 MAJOR PROJECT DELIVERABLES • Tech Memo 1 - Heat to Energy: Condition Assessment of Steam, Energy & 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 - Pre-Design Report (PDR): 10% Pre-Design Report for selected alternative ' 9 STEAM PROJECT UPDATE By TASKS (% COMPLETE) Tasks Condition Assessments Completed Draft Condition Assessment Reports, 01 low Updates Submitted,and Board Presentations Comprehensive Asset Evaluation Completed Draft Comprehensive Asset Evaluation 02 90% Technical Memoranda(TMs)and held Workshops. tOutstanding items are the Executive Summary and 1....................... .0 ate to Corrvmittee/Board Secondary Process&Steam System Optimizations Completed Field Work/Analysis.Outstanding items 03 80% are submitting draft TMs and providing an update to t Committee/Board 1__________________________________I Business Case Evaluations(BCEs)and Peer Review Completed Electric Blower BCE and Developed List of 04 33%) BCEs/Alternatives.Outstanding items are BCE t I completion and update to Committee/Board 1__________________________________I Preliminary Design Reports(PDRs) Completed Draft PDR for Electric Blowers. 05 30% Outstanding items are PDRs developed under BCEs and update to Committee/Board 1. 10 CENTRALSAN January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 50 of 66 5 Page 7 of 14 STRUCTURAL ANALYSIS OF AERATION BASIN & CLARIFIERS FINITE ELEMENT ANALYSIS MODEL: USED FOR ANALYZES AS A PART OF TASK 1 & 2 - COMPREHENSIVE ASSET EVALUATIONS �N ' axpanslvn Jvint uv channel moemcanona �` Aeration Basin Structure Secondary Clarifier Structure FEA Finite-Element Analysis(FEA) CENTRALSAN TASK 2: DRAFT STEAM SYSTEM COMPREHENSIVE ASSET EVALUATIONS Solids LEGEND Pumpingcaff"Lw 'M FM Water and : . - ■: : t Ralahle Cdd! psprKpr Water SW.MTank ,! Efs.-d CwM"w [w ____y Pe,urn__z! LlY a iz CENTRALSAN January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 51 of 66 6 Page 8 of 14 TASK 2: DRAFT SECONDARY COMPREHENSIVE ASSET EVALUATIONS Asset Name Locationr}rry Y 5 - Aeration Air Filter s IIIIIIII r. s>«� eT+ Aeration Shakers 6 K. Blower Inlet Guide Vanes#1 and#2 III 2111111' 5 Blower Inlet Guide Vane#3 ■ Blowers#1and#2 3A (E ■ 7Blower#3 I Aeration Headers 4A• la; S®!® Aeration Headers(Where it Crosses the Effl.Channel) 4JJ ■■�® 5 __fes .. 12 Aeration Piping 6 Aeration Air Control Valves - Aeration Plenum 7 11111111 oil Diffusers d 17 s 111119 111 1.7 1 i2 Aeration Basins 9 NorthMixed Liquor Channel 10A* �e i9 f �r T South Mized Liquor Channel 10B" Secondary Clarifier Basins 11 'C—In Secondary Clarifier Mechanisms: ,-' 12 Grouped by Near-Term Replacement �- — SecondaryClarifierMechanisms: ® LEGEND , Grouped by Immediate Replacement s. Secondary Clarifier Inlet Gates(Except South Clar.#4) 1111111111 1 -{.� Secondary Clarifier#4 Inlet Gate 15 'T8D pending i nspeclion r North RAS Pumps 16A South RAS Pumps 16B RAS Piping—General 17A RAS Piping—Submerged in Channel WAS Pumps and Suction Piping 18 13 WAS Piping 19 Tunnels 20CENTRALSAN TASK 2: ELECTRICAL SYSTEM COMPREHENSIVE ASSET EVALUATION 4 R 0 - 0) _ j f��-rr�Im��y�ryr�SYlf�r6� � 1 irya� p ry 400 ) •. -IlI�11/t� Yi1L'fiaol. I�� F:.�:, CENTRALSAN J Iffld11311� January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 52 of 66 Page 9 of 14 BIOLOGICAL PROCESS OPTIMIZATION AS A PART OF TASK 3 - SECONDARY PROCESS & STEAM SYSTEM OPTIMIZATIONS Wastewater Characterization The findings from these efforts have resulted in Essential to 1)understand overall plant performance the following: and 2)model optimization/upgrade options ' water quality 2) Plan . .. A/N Tank Feed Flow Split Evaluation i. Address A computational fluid dynamics(CFD)modeling to ii. Improve the secondaryprocess(slu..- understand the existing flow split settleability,aeration,flow split) iii. Inefficiencies with existing diffusers Anaerobic Selector Optimization iv. Opportunities to address conveyance Understand how the process is behaving and bottlenecks '" ' opportunities to improve settleability ....0 Off-Gas Testing Evaluate the oxygen transfer efficiency in the A/N tanks Hydraulic Profile Identification of hydraulic bottlenecks that is limiting conveyance capacity at flows> 100 million gallons per day is CENTRALSAN LIST OF BCES AND ALTERNATIVES (ALL THE BCES WILL INCORPORATE ELECTRICAL PRELIMINARY FINDINGS FROM COMPREHENSIVE ASSET EVALUATION) 1. BCE#1: Electric Blowers versus Existing Steam Blowers (Short-Term; completed and in Design): • Dedicated Blowers sub-BCE (as part of Blower Design) Secondary System 2. BCE#2: Aeration Basin Diffusers: • Alt #2A: Business As Usual (BAU) • Alt #213: New Diffusers (Plenums under Investigation; Water Exchange under Consideration) Steam Electrical System System 3. BCE#3: Secondary Process Improvements: • Alt #3A: BAU • Alt #3B: BAU + Improvements (includes pending Diffusers/Plenums BCE#2) • Alt #3C: Water Exchange + Improvements • Alt #3D: Nutrient Reduction + Improvements 16 January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 53 of 66 8 Page 10 of 14 LIST OF BCES AND ALTERNATIVES (ALL THE BCES WILL INCORPORATE ELECTRICAL PRELIMINARY FINDINGS FROM COMPREHENSIVE ASSET EVALUATION) 4. BCE#4: Steam System (Long-Term Blower Lead; Water Exchange and Landfill Gas Long-Term Viability under Consideration): • Existing Steam Blowers in Lead: Secondary ➢ Alt 4A: BAU (Retain Steam Blowers; Electric Blowers as System Back-Up) ➢ Alt 4B: BAU (Retain Steam Blowers) + Improvements (Electric Blowers as Back-Up) 7 • New Electric Blowers in Lead (Paradigm Shift): ➢ Alt 4C: Electric Blowers + Improvements (Steam Blowers Steam Electrical as Back-Up) System System ➢ Alts 4D/E/F: Paradigm Shift (Electricity Production; Steam Blowers Phased Out) 0 4D: Electric Blowers + Improvements + Steam Turbine Generator(STG) 0 4E/F: Electric Blowers + Improvements + Expand/Replace Cogen 17 BUSINESS CASE EVALUATIONS (BCES) NW #3 FOR SECONDARY SYSTEM Aeration Air Filters IA Aeration Shakers 113 ®�®' Blower Inlet Guitle Vanes"and Q 2A Blower Inlet GUltle Vane N3 213 Blowers#1 antl p2 3A Blower a3 3BAlternative#3A: Business Aeration Headers 4A TBD3 Aeration Headers 4B TBW As Usual Aeration Piping 5 Aeration Air Control Valves 6 Aeration Plenum 7 Diffusers B ----- Aeration Basins 9 ®i ®i � TBD3 Alternative h ----- NortMixedDquprChannel l0A ®®® TBD3 South Mixed Liquor Channel 10B ®i ®i ®i TBD3 ■ Secondary Clarifier Basins 11 Secondary Clarr Mechanisms: 12 � Secondary Alternative Grouped by Near-Term Replacement Secondary Clarifier Mechanisms: 13Syste ®®®® Grouped by Immediate Replacement Exchange + (F—pt ryCla Chri,r#4)ates 14 ®®®® �Excepl5ou[h Clarifer k0) Improvements 5—dary Clarifier#4lnlet Gate ----- NorthRASPumpsAlternative#31): Nutrient Sou16 th RAS Pumps 16B RAS Piping 177 Reduction WAS Pumps 18 WAS Piping 19EMMM Improvements TUnne155y— 20 UL of�20years,blue cells have an RUL of 1030 years,yellow cells have an RUL of 510 years,res cells M1ave Lof.S ed iigoj. rgs grapM1irzllyrprovitletl In Figure 41. antl/or[M1e final report.For tM1e laser,zucM1 assets will be inspectetl on they are taken off-line and available for nzpettlpn savaJable over project tluratlpni. azedon tM1pimost vulnerable m olocation,whichisantidpair,wM1ere the aeration header<roszez[be efRuent channel.At[his."i"m me viva is awie<tea me liRma,atmoevnen<aic aid aimow irttedaa. antl Secondary Clariferarelimp by hytlraullc capanty iup to 100 mgtl perfM1e CompreM1ensive wastewater e ank SurA reu will baa endedd wi-1,11— ng hytl au is an sizj. 18 January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 54 of 66 9 Page 11 of 14 BUSINESS CASE EVALUATIONS (BCES) #4 FOR STEAM SYSTEM TahW 4-1.Sioam System Comprollansiro AS sol EraPuatlon RIA Summary' 100® Caoa.a OJ"IC.grm)SrA-9aik. 9awiv ty )N1 GIMHF]W.a[.HeM IIIII�III®®® ,4odlar 6d1Nr Nl and N2 �WIpyN Ha Wn.r Flwn Exrnvgr �� < Alt 4A:BALI Alt:b�iSI.ino Blow s= Cha.akel Feed liyoa^(Long-Term use) Oeeefa[e15[efaye ienk ®®0' 4B:BALI+Improvements L.mdrraM(Gets[}5[way.r-k ��® z L.anYetoua B6waown Flats Talc ��®� I.wxWI BN»dam Fixn imk �� waw^ mrai andh �� Bpd$C.-Al .0 8-k"WAO um 4C:Improvements WOO 90w Feed PiWV W Bvaa Feat P. p P Ele[Ule 9eaa Fee.Pump AeW.WQ Stern T".N1 end N2 Wmd 5lwnFxchaN$F N1 ®�®� —Alt New Electric ,� Watq S4Ma Expyrptr>? �®� Hen R'viwM 8flta/•ExWrgre�- A�3��®� r„edv Gyre sew cord..:..Blowers as Lead (Long-Term use) rdtdp.yde P1/nPNI sr1 Nx ��®� npne e.ewrcl Cordenra,Nl a,d Nz ��®: .:� Vaeum H.p1r ftw Si Separ&or Nland N2 NWS-sk Ali cabereaee Ppkq �®®0 119 •wM=..m�..n....,Rug a,sow••.uw ow n...�Au.w+o-avrw.r.�-a..n..,...mn ds+o BCE NON-ECONOMIC CRITERIA (BUILDS ON THE CONDITION ASSESSMENT & COMPREHENSIVE ASSET EVALUATIONS) 1. Technology Status: Based on the number of installations globally and within the US. 2. Safety: That point in the future (years) when safety issues preclude or significantly inhibit the operation of the asset. 3. Operating Ease: That point in the future (years) when operating complexity precludes or significantly inhibits the operation of the asset. 4. Maintenance, Redundancy, & Reliability: That point in the future (years) when increasing maintenance precludes or significantly inhibits the operation of the asset. 5. Long Term Flexibility: That point in the future (years) when improvements in efficiency or technology would justify replacing the asset. 6. Cap and Trade: Would the alternative put Central San in a position where they would enter Cap and Trade under Senate Bill 32 (i.e., >25,000 MT CO2/year). 21) CENTRALSAWN January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 55 of 66 10 Page 12 of 14 NEXT STEPS .1211 BCE INCORPORATES ECONOMICS AND NON-ECONOMICS CRITERIA TO INFORM DECISION MAKING List of Alternatives e _r BCE BCE Incorporates Economics and Non- Economics to Inform Decision Making cost —Score for each Alternative Non-EconomicsoBenefit _ Total NPV Cost(Capital+0&M) Economics per Alternative Benefit Score(i.e.,Non—Economics) Key Definitions: Business Case Evaluation(BCE)=Overall System Decision Making(e.g.,Steam System has 1 overarching BCE) Alternative=BCE subgroups that make up the BCE CENTRALSAN January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 56 of 66 11 Page 13 of 14 QUESTIONS? ' 23 SOLIDS TREATMENT ENERGY DISTRIBUTION PS Mending Ce t to MHF1 GAFU 9� n� f,^5 lank100% WA LN101u�d WOMM 11w17 Ah m i90 ky.19"a er lonriNN 90 kW 150 kW i',i{I F I O7M STl1M ZO LN61'L 30 U:tl �ppyy E CiriCtlJ1 woBol Bolter 1vhM9Tu.b FH Boirer 1 2aln ue 5 To L14'uId Trea unerlr To ONMr SO we" 417 WO lohn Y .111111h. SOKCN a70 w9h,n �i "11 W" 190 kW A x1la a ,. ,R16 J❑ 70 M,BTIJrt1 Mara Tota! - Torar 1 Land1771 Gas iO SRfC§u+tl 700016•1, Plan[ a nsurnptha nn�r.tilr=I�.•I 'y ABO w 10G•.o.' Steam F24o kwmu•e C O�:Pfl Prat On To Steam TetatNatural a oogra, Turbine ;onsum GasTurbine "�[A'� Aeration sum r leorkra nsorFx"d Blowers 1./06 Ll.1i01rt[ 7,5nO kW -Be AaA9TWd LAmnnLt, NATURAL SPLIE1s s POWF77 STEAMGA5 GAB v Flgura 7.47 Sankey Diagram of Solids Traaanent and Energy Recovery Energy Distribution ' 24 January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 57 of 66 12 Page 14 of 14 LIQUID TREATMENT ENERGY DISTRIBUTION Nvaaw pt" w T. v Raw ��yow.ma Mlmlua ■ saw�a M.6Nk� ievuem T PS WAS saaa wauAerue says IW wa*ua saa Prn nmo wn sr..n eoo wanes a 2�w m v vtrwrtiun�-- r° "' fv oal.l ie awe Tv Fllrr • Preaaraa Plee...rlg Pref W-81- -U. foAWiu� SOLIDS s POWER eTPAM Figura 7.46 Sankey Diagram of Liquid Treaanent Energy Dimbutian 7 go H MAIN PROJECT FOCUS AREA Head-A, Pnn'n7 Tv R-rJ g II GU"— wW. 7v OuEaA M to Rees solves 020 BTiltl :2U].RA tl mnuem PS W wea soo a sale. R,Iw.a.ua dal PIenI Y].Yeo An Sfesm 90a L1LIaTllM 11 CCC Iefi 9.r.FM1RTI I•n '�°�° HtlRIrM a rf AVS E 3Vl ene�:. FW e l �. en lyln'��h m Tia Pr T°61h°r Yi..t ivuarr Ta Sellda Iv Files �P"9ae Plxenn Pleeauila Prn IlntHi.•f l.l...11 11•I fuUl•Mllue tm wtv ,y l,ftail le S L[S S POWER BTF Figure 7-46 Sankey Diagram of Liquid Treatment Energy Oiseibutian January 19, 2021 EOPS Regular Committee Meeting Agenda Packet- Page 58 of 66 13