Sweet Home WWTP Upgrades Project...unforeseen challenges (e.g. NPDES Permit, Industrial Growth,...
Transcript of Sweet Home WWTP Upgrades Project...unforeseen challenges (e.g. NPDES Permit, Industrial Growth,...
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Sweet Home WWTP Upgrades Project
March 2019
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Project Foundation
“…make decisions that do the most good, for the most people, for the longest period of time”
Source: 2017-18 City Council Goals
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Agenda
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Introductions Project History 20% Schematic Design
Base Upgrades
Additional Project Elements to Address
Unanticipated Challenges
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QuestionsSchedule and Next Steps
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Introductions
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Team Introductions
Preston Van Meter, PEProject Manager
Austin Rambin, PEProject Engineer
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Jessica CawleyStaff Engineer
Patrick DavisStaff Engineer
Greg SpringmanPublic Works Director
Trish RiceEngineering Technician
Steven HaneyWWTP Project Manager
CITY AND WWTP MURRAYSMITH
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Project History
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Original Facilities Plan Review
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Future Rates: ~$95/month
Original Recommended Plan:• $42 Million over 30 years• Separate Peak Flow Process• Limited Rehabilitation
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Continue Collection System Focus
Peak hour flows do not account for
future population growth or
expansion of the City’s service area
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5
10
15
20
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11/21/71 11/23/71 11/25/71 11/27/71 11/29/71 12/1/71 12/3/71
Flo
w,
mgd
Simulated Storm Date
Pre-Rehab Peak Hour Flow
Post-Phase 2 Peak Hour Flow
Post-Phase 3 Peak Hour Flow
Post Phase 4 Peak Hour Flow
WWTP Capacity
Existing WWTP Capacity: 7 MGD
Req’d WWTP Capacity: 12 MGD
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Continued Collection System Focus• Allow for future growth (1.8 MGD in
additional peak flow, per 2016 Facility Plan)
• Address aging collection system
• Maintain WWTP Flow < 12 MGD
$3 - 6M of targeted collection system rehabilitation:• Remove ~2 MGD of RDII over next 20 years• To be completed in-house by City staff• City working on manhole sealing now 9
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Existing WWTP Review
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Upper Plant –Expansion Area
Lower Plant –Existing Facility Area
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Existing WWTP Challenges
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• Secondary only, complete mix process
• No Headworks (rags everywhere)
• Early 1990’s upgrade added tertiary sand filters
• Undersized CCB & outfall• Inadequate Aerated Sludge
Storage Basin• Dewatering Facility with
significant code violations• Limited SCADA/automation
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“3R” Asset Management Approach
▪ Rehabilitate existing structures
▪ Reuse existing assets
▪ Re-purpose existing processes/areas
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Co
ndit
ion
Age
Rehabilitation MORE cost-effective
Rehabilitation LESS cost-effective
Rehabilitation @ Half the Cost of New Construction – if done timely!
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Targeted Avg. Monthly Wastewater Rate
~$30/month lower
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20% Schematic Design Base Upgrades
Sweet Home WWTP
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Schematic Design – Base Upgrades
Primary Digester
Mechanical Building
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Secondary Digester
Secondary Clarifier
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Primary Clarifier
Secondary Clarifier 3
Secondary Clarifier 2
Secondary Clarifier 1
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Schematic Design – “3R” Elements
Secondary Clarifier
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Primary Clarifier
Primary Digester
Mechanical Building
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Secondary Digester
“3R” Elements: • Influent Pump Station (IPS)• Aeration Basin Expansion• Secondary Clarifiers• Chlorine Contact Chamber• Aerobic Digester
Secondary Clarifier 3
Secondary Clarifier 2
Secondary Clarifier 1
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Influent Pump Station
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Reuse and rehabilitate existing influent pump station wet well saves $$ for other upgrades
Estimated Cost - $2.1 M
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Headworks Screening and Grit Removal
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Construct new headworks with grit removalto improve overall process and biosolids quality
Estimated Cost - $2.9 M
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Primary Clarifier
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• Add one new primary clarifier• Provisions for future
expansion
• Allows plant solids process to be converted to anaerobic digestion• Eliminates energy-
intensive aerobic process
• Provides possible incentives from Energy Trust of Oregon (ETO)
Estimated Cost - $1.7 M
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Aeration Basin Modifications
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Estimated Total Cost - $3.5 M
• Extend and rehabilitate the existing basin
• Change the flowpath
• Improve aeration
• Improve operational flexibility
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Secondary Clarifiers
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Rehabilitate 3 existing Secondary ClarifiersAdd one new (larger) Secondary Clarifier #4
Estimated Cost - $2.4 M
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UV Disinfection
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Convert existing CCB to Ultraviolet (UV) Disinfection
Estimated Cost - $1.3 M
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Solids Thickening
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Construct new Storage/Thickening Building Install Sludge Thickening Equipment
Estimated Cost - $0.9 M
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Solids Digestion
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Construct new Primary Anaerobic Digester Convert existing Aerobic Digester to Secondary Anaerobic Digester
Estimated Cost - $3.1 M
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Solids Dewatering
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Demolish Existing Dewatering Facility
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Solids Dewatering• New Dewatering Building
on Upper Plant Area
• Cost-effective Premanufactured Metal Building • Enclosed screw press• Covered “cake” storage area
• Produce high quality Class B Biosolids product
• Class B gives City options to eliminate $130,000/year landfilling fees
• Class A Biosolids provide more disposal options
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Estimated Cost - $1.3 M
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Civil Site Improvements• Site entrance and
accessibility • Site security• Stormwater
management
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Estimated Total Cost - $1.5 M
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Electrical and SCADA Improvements
Estimated Electrical Cost - $2.3 MEstimated Automation Cost - $0.5 M
• 3 Electrical Rooms on site• Central CP in Administration Building
• Redundant PLC’s • Remote I/O in other Electrical Rooms
• Provide remote login capability for Plant Staff • Plant Wifi Network with operator tablets
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Base Project Cost SummaryBase Project Costs(1)
Influent Pump Station $2,100,000
Headworks Screening and Grit Removal $2,900,000
Primary Clarifier $1,700,000
Aeration Basin Modifications $3,500,000
Secondary Clarifiers $2,400,000
UV Disinfection $1,300,000
Solids Thickening $900,000
Solids Digestion $3,100,000
Dewatering and Biosolids Storage $1,300,000
Civil Site Improvements $1,500,000
Electrical and Instrumentation $2,800,000
Subtotal of Base Project Costs $23,500,000
30(1) Costs include markups for General Conditions (8%), Mobilization (8%), Contractor O&P (12%), Design Contingency (20%), Construction Contingency (10%), and Engineering, Legal, and Contract Administration (25%)
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Additional Project Elements to Address Unanticipated Challenges
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Unanticipated Project Elements
Primary Digester
Mechanical Building
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Secondary Digester
1. Tertiary Filters & Mass Load Limits2. New Administration Building3. Class A Biosolids Composting
Secondary Clarifier
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Primary Clarifier
Secondary Clarifier 3
Secondary Clarifier 2
Secondary Clarifier 1
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Existing Tertiary Sand Filters
• Sand filtration not generally good in WW treatment
• Requires pumping
• Limited capacity• 2 to 4 MGD
• Uses Chlorine• Converting to UV disinfection
• Difficult to operate
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NPDES Permit Limits
• NPDES Permit Expired in 2010
• Mass Load Limits may limit discharge in future as ADWF increases
• Pursue Mass Load Increase through DEQ• Anti-Degradation Evaluation
Required
• Recommend keeping tertiary filtration to maximize potential for mass load increase
2043 ADWF = 1.85 MGD (34% increase)
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New Tertiary Filter Option
Total Cost - $1.85 M
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Admin Building Rehabilitation
• Significant exterior upgrades required• Men’s locker room is marginal and there is no women’s locker room• ADA access issues throughout building• Undersized and poorly laid out WQ Laboratory• Few operator/staff works stations 36
Total Cost - $1.25 M
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Offsite Class A Biosolids Composting
Covered Compost Pile at Florence OR WWTP
Estimated Total Cost - $1.6 M
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Biosolids Composting Layout
20-yr BuildoutPhase 1
Estimated Total Cost - $1.6 M
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Why Class A Biosolids Composting?
• EPA-approved, sustainable solution to resolve biosolids disposal problem
• Exceptional Quality Class A Biosolids can be beneficially reused on City parks, open spaces and provided to ratepayers with no restrictions• No restrictions on Class A Biosolids once it leaves the site
• Not subject to the whims of third-party material receivers as required for Class B Biosolids land application
• Create a high quality, valuable product that would save $130,000 in annual landfill tipping fees
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How to Compost Biosolids?
• Treated biosolids are mixed with green waste (wood chips, leaves, grass clippings) collected from City streets and parks
• Compost piles are aerated to provide oxygen for aerobic microbes
• Compost piles are continuously monitored to meet EPA minimum temperatures to kill pathogens
• 4-6 weeks later the compost is ready for public use
• Composting requires adequate room for material storage and equipment movement (1+ acres present day / 2.5+ acres full buildout)
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Additional Project Elements Cost Summary
Additional Element Costs (1)
Tertiary Filter $1,850,000
New Administration/Lab Building $1,250,000
Offsite Class A Biosolids Composting Facility (Phase 1) $1,600,000
Subtotal $4,700,000
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(1) Costs include markups for General Conditions (8%), Mobilization (8%), Contractor O&P (12%), Design Contingency (20%), Construction Contingency (10%), and Engineering, Legal, and Contract Administration (25%)
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Total Cost Summary
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Compiled WWTP Costs for Base and Additional Elements (1)
Estimated Base Cost $23,500,000
Additional Elements Cost Summary $4,700,000
Additional Elements Subtotal $28,200,000
(1) Costs include markups for General Conditions (8%), Mobilization (8%), Contractor O&P (12%), Design Contingency (20%), Construction Contingency (10%), and Engineering, Legal, and Contract Administration (25%)
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Providing for future WWTP expansion beyond 20 year planning horizon
• Additional channel for additional influent screen in Headworks
• Provide piping for adding second Primary Clarifier in future (if needed)
• Providing for future Aeration Basin Capacity expansion (if needed)
• Provide for future filter capacity expansion (if needed)
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Long Term O&M Considerations
“…make decisions that do the most good, for the most people, for the longest period of time”(2017-18 City Council Goals)
Proceeding with the $28.2M project offers:• “3R” Approach brings aging facility back to life for 40-50 years
• Full plant automation reduces staffing requirements and cost
• Upgrades provide for cost-effective expansion in future to address unforeseen challenges (e.g. NPDES Permit, Industrial Growth, etc.)
• High quality compost eliminates $130k/year in landfill costs and provides a valuable end product for use by the City and residents
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Project Funding Update
• City funds. With recent WW rate increase, the City is now building considerable reserves to support the project.• Currently projecting ~$7M in local funds at start of construction
• Earmark Funding. City is currently utilizing a $2M earmark from the Oregon State Legislature, with potential for another $3M earmark this legislative session.
• USDA Grant Discussions. Initial discussions with USDA indicate a grant of up to 25% of the unfunded balance may be available.
• ETO Incentives. Currently working with the Energy Trust of Oregon to identify energy efficiency incentives for the project.
• Loans. Currently discussing loan funding with multiple agencies.
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Schedule and Next StepsSweet Home WWTP
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Overall Project Schedule
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Next Steps• Proposed Public Process:
• Public Hearings on March 26th and April 9th
• City Council Decision to proceed with project on April 23rd
• Finalize Schematic Design (USDA PER & ER)
• Contigff*fc=nue coordination with Oregon DEQ on NPDES Permit• Anti-degradation Evaluation for Mass Load Increase• Work to get NPDES Permit Renewal on DEQ Schedule
• Continue work to determine project funding (USDA, DEQ, etc.)
• Update rates and SDCs
• Proceed with final design in June• Murraysmith final design & CM proposal to be provided in May 48
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Questions?
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