Sugar Creek WWTP – CMAR Project Delivery for · Sugar Creek WWTP – CMAR Project Delivery for...
Transcript of Sugar Creek WWTP – CMAR Project Delivery for · Sugar Creek WWTP – CMAR Project Delivery for...
© 2014 HDR, all rights reserved.
Nicole Bartlett, Kit Eller, Charlotte Water;Will Shull, Mary Knosby, Brian Thorsvold, HDR;Matt Reaves, Patrick Costello; Garney
Sugar Creek WWTP –CMAR Project Delivery for Reliability Improvements
2018 NC AWWA WEA Spring Symposium March, 2018, Asheville
01 Project Background / Drivers
02 Project Execution
03 Reliability Improvements
Topics for Today’s Presentation
04 Project Delivery
© 2014 HDR, all rights reserved.
Project Background / Drivers
01
Charlotte Water’s oldest (1920’s)!
Permitted for 20 MGD but operates at 13 MGD due to shared Phosphorus bubble limit.o Excess flow is diverted to McAlpine Creek WWMF
Influent loads are increasing despite total flows decreasing.
Primary Sludge and WAS is diverted to McAlpine Creek WWMF
Sugar Creek WWTP
Project Background / Drivers01
Identify required plant upgrades to reliably treat 16 mgd dry weather flows, and 30 mgd wet-weather peaks
Add Chemical Phosphorus Removal
Meet all NPDES permit requirements
Energy Efficiency and Optimization
Budget
Objectives
Project Background / Drivers01
Focus areas to meet objectives/compliance requirementso Main Lift Pump Stationo Aeration System o Phosphorus removalo Chlorine Contact demolitiono Potable/Non-Potable systems o Effluent Filters o Instrumentation & Controls
Focus Areas
Project Background / Drivers01
© 2014 HDR, all rights reserved.
Project Execution
02
Clean Water State Revolving Fund (CWSRF)o 60% was Green = 0% interest
• Energy efficiency component (savings of approximately 40%)o 40% was not = 1.66% interest
SRF Special Conditionso American Iron & Steelo Davis Bacon
FundingProject Execution02
Project Execution
Organizational ChartConstruction Manager at Risk (CMAR)
Engineer CMAR
Owner
Trade ContractorsSuppliers
02
Qualifications based selection Obtain Contractor input during design Contractor develops GMP (open-book) Building to budget Better opportunities for o Charlotte Small Business and Minority Business Enterpriseso At higher participation percentages
Achieve more certainty o Project cost and scheduleo Mitigate risko More effectively coordinate construction and startup
Boils down to no major surprises
CMAR BenefitsProject Execution02
OWNER ENGINEER
FUNDINGCONTRACTOR
© 2014 HDR, all rights reserved.
Reliability Improvements
03
Reliability Improvements Main Focus Areas
I’m sure we have a more recent site plan or I could BB something
Reliability Improvements03
Improvements Purposes Benefits
Replace existing blowers with high speed turbo blowers
• High speed turbo blowers will achieve full range of flows and operate more efficiently
• Blowers are approximately ~18 years old now
• Regulatory Compliance • Energy Savings• Reduced Maintenance
Replace and Redistribute Diffusers
• Optimize diffuser flow rates in the first aeration zone• Better match projected zone air demands
• Energy Savings• Process enhancement • Regulatory compliance
Implement Ammonia Based Aeration Control (ABAC)
• Reduced air demands by approximately 25 to 35% compared to DO based aeration control
• Reduced supplemental alkalinity requirements
• Energy Savings• Chemical Savings
Pre-anoxic swing zone addition
• Alkalinity recovery• Reduced air demands in downstream aeration zones• Reduced total nitrogen discharge loads• Reduced potential for denitrification in the FC solids blanket
• Chemical Savings• Energy Savings• Environmental / Regulatory • Less frequent filter backwash
Additional Aeration System Improvements Reliability Improvements03
Reliability Improvements03Aeration System Improvements
Existing AB Splitter Box• Constructed in the 1950s• Uneven flow split, even with attempts at
adding weir plates• AB 9 currently getting most loading
Improvement Purposes BenefitsAeration Basin Influent (ABI) Flow Distribution Structure
• Existing splitter is undersized and incapable of providing a reasonable flow split between the aeration basins
• Unreliable treatment and inefficiencies• Ammonia breakthrough
• Regulatory Compliance• Process Optimization• Energy Efficiency
Reliability Improvements03Aeration System Improvements
INITIAL CONCEPT 1:3 SCALE MODEL
Improvement Purposes BenefitsAeration Basin Influent (ABI) Flow Distribution Structure
• Existing splitter is undersized and incapable of providing a reasonable flow split between the aeration basins
• Unreliable treatment and inefficiencies• Ammonia breakthrough
• Regulatory Compliance• Process Optimization• Energy Efficiency
Reliability Improvements03Aeration System Improvements
PRE MODIFICATIONS BAFFLE MODIFICATION POST MODIFICATIONS
Improvement Purposes Benefits
Replace 18 year old extended shaft vertical centrifugal pumps with dry pit centrifugal pumps
• Existing pump type is maintenance intensive
• Replacement parts not readily available
• Improve safety maintaining pumps
• Pumps will match existing Influent Pump Station with significantly reduced maintenance
• Selected pumps will operate at best efficiency point• Reduce risk of excess flow diversion to McAlpine• Safety improvements with new pump type:
• Pumps will not require special rigging to remove for maintenance
• Platforms to provide safer / easier access to maintenance components (currently use step stool ladder)
• No exposed rotating shaft
Main Lift Pump Station Improvements Reliability Improvements03
BIM image from revised pump station layout
Photo
Reliability Improvements03Main Lift Pump Station Improvements
LIDAR SCANClearance b/t supports
Pipe size verification and location
Outdoors also!
Pump access Maintenance Safety
Proposed Existing
BIM image from revised pump station layout
Photo
Reliability Improvements03Main Lift Pump Station Improvements
LIDAR SCANClearance b/t supports
Pipe size verification and location
Outdoors also!
Demolished overhead supports for pump access/maintenance
Proposed – Upper level looking downExisting – Lower level looking up
BIM image from revised pump station layout
Existing pump station layout
Reliability Improvements03Main Lift Pump Station Improvements
LiDARo Terrestrial LiDAR (Light Image, Detection and Ranging) is a survey method that
uses a laser to capture points of 3D information. This technology is also referred to as laser scanning, 3D scanning and high-definition scanning.
Main Lift Pump StationLiDAR Instrument & Tripod
BIM image from revised pump station layout
Photo
Reliability Improvements03Main Lift Pump Station Improvements
LiDAR SCAN
LiDAR Benefits/Useso Access to site without being thereo Record drawings vs. actual (field verification)o Ability to take accurate measurementso Clash detectiono Drawing generation
BIM compatible
BIM image from revised pump station layout
Photo
Reliability Improvements03Main Lift Pump Station Improvements
LIDAR SCAN
LiDAR Benefits/Useso Access to site without being thereo Record drawings vs. actual (field verification)o Ability to take accurate measurementso Clash detectiono Drawing generation
BIM compatible
Clearance b/t supports
Pipe size verification and location
BIM image from revised pump station layout
Photo
Reliability Improvements03Main Lift Pump Station Improvements
LIDAR SCAN
LiDAR Benefits/Useso Access to site without being thereo Record drawings vs. actual (field verification)o Ability to take accurate measurementso Clash detectiono Drawing generation
BIM compatible
Clearance b/t supports
Pipe size verification and location
Outdoors also!
© 2014 HDR, all rights reserved.
Project Delivery
04
Project Delivery
CLTWater select Engineer
Complete PER
Select CMAR to onboard as engineer
is beginning design of alternatives
selected in PER
SOQ/Interview for CMAR Selection
Design with CMAR including
Constructability Review, Value
Engineering & Cost Estimates
Strategic Bid Packaging and Process
Equipment Evaluations Process
Prequalification's & Selections
Bidding & GMP Development
Construction Manager at Risk (CMAR)04
Scope Development
Preliminary Engineering Report
CMAR Selection
30% Design & CMAR Pre-Con Services
60% Design & CMAR Pre-Con Services
90% Design & CMAR Pre-Con Services
Sub & Vendor Bidding Permitting
CMAR GMP
CMAR GOALS & OBJECTIVES
Keep plant in compliance/maintain plant operations, Create a solid plan for startup/training/O&M’s, Site specific safety plan (including ISO program), Updates to plant SOP’s for maintenance & operation, Maximize Budget (cost estimates & Value Engineering), Design efficiency (proactive not reactive), Ease of O&M considering energy/life cycle/usability/longevity costs, Successful permitting (NC DEQ ATC, Erosion Control, & Mecklenburg County Building
Standards), SRF funding and contingencies, Decision making to maintain schedule.
First Action as a Team – Define Goals04 Project Delivery
Division of Responsibilities Based on Team Goals
MOPO Plans – developed early and updated as design gained detail
Formal cost estimates at 30, 60 and 90%
Value Engineering and constructability reviews
Ongoing cost opinions/estimates to support equipment decisions
Preconstruction Schedule
CMAR Preconstruction Responsibilities04 Project Delivery
Divert flow to EQ Close slide gates at headworks Run one pump to el 566 Use temp pumps to empty wetwell to
McAlpine bypass Open check valve to drain force main Lock Out VFD/SWBD for Pump 1 Replace suction valve Install bubbler in wetwell Replace discharge valve Return flow to wetwell Install, startup and test pump 1 Repeat for 2, 3, 4
Main Lift Pump Station MOPO04 Project Delivery
Developed MOPO and sequence based on 60% design
Pre investigative work (potholing)
Revised piping layout and increased demolition scope based on what we found
Increased confidence in design and prevent delay in construction
Aeration Basin Influent Structure04 Project Delivery
Division of work packages evaluated at 60% design Two Options – By Process Area or By Trade/Section Selected Process Areao Lower potential for scope gap or overlapo Fewer schedule and coordination issueso Easier to meet SRF MBE requirements o Lower contingency
Subcontractors and Packaging04 Project Delivery
Package 1 – Blower Building Foundation and Building
Package 2 – Chemical System and Piping
Package 3 – Final Clarifiers
Package 4 – Main Plant Process Civil and Mechanical
Package 5 – Electrical Package 6 – Mass
Demolition Package 7 – HVAC and
Plumbing
Subcontractors and Packaging04 Project Delivery
Cost Estimate Overviewo 30% Estimate - $23.8 milliono 60% Estimate - $25.6 million o 90% Estimate - $25.1 million
Final Review Milestone @ 90% - Cost Estimate and VE Reporto $4.2 million in VE ideas identified, $2.7 million incorporatedo 90% Reconciled Estimate of $ 24.9 million
HDR prepared final documents & Garney prepared bidding documents Held bid opening & Reviewed bid packages Found low bidders to be responsive for all packageso Harper Corporation – Packages 1, 2, 3, 4, and 6o Crowder Construction Company – Package 5o Southeastern Plumbing – Package 7
Total Final Project Costs of $23.5 milliono GMP consists of sum of packages 1-7 + CMAR Costs + Project Contingencyo Owner Contingency
Guaranteed Maximum Price Development04 Project Delivery
Construction Contract approved by CLTWater on 2/12/18 Authorization to Construct on 2/16/18 County Building Standards Approval on 2/22/18 Contracts Executed and NTP on 3/22/18
MOBILIZED AND READY FOR CONSTRUCTION!
Mobilization and Schedule04 Project Delivery
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