ncsu centennial campus reuse water concept report

North Carolina State University Centennial Campus Reuse Water Distribution Concept and Budget Report AEI Project No. 13108-00 Issued: April 5, 2013

1414 Raleigh Road Suite 305 Chapel Hill, NC 27517 919-419-9802 www.aeieng.com

Table of Contents

EXECUTIVE SUMMARY 1. PROJECT OVERVIEW ................................................................................................................................ 1

2. CONNECTED LOADS ................................................................................................................................. 1

2.1 CENTENNIAL CAMPUS CUP ........................................................................................................................... 1 2.2 HUNT LIBRARY ............................................................................................................................................ 1 2.3 OVAL IRRIGATION ........................................................................................................................................ 2 2.4 FUTURE COLLEGE OF TEXTILES CUP ................................................................................................................ 2 2.5 FUTURE IRRIGATION CONNECTIONS ................................................................................................................ 2 2.6 DEMAND SUMMARY .................................................................................................................................... 3

3. REUSE WATER DISTRIBUTION .................................................................................................................. 3

3.1 PUMPING STATION ...................................................................................................................................... 4 3.2 DISTRIBUTION PIPING................................................................................................................................... 5 3.3 CONNECTION REQUIREMENTS ........................................................................................................................ 6

4. PROJECT PHASING AND BUDGETS ........................................................................................................... 6

4.1 PHASE ONE ................................................................................................................................................ 7 4.2 PHASE TWO ............................................................................................................................................... 7 4.3 PHASE THREE ............................................................................................................................................. 8 4.4 PHASE FOUR .............................................................................................................................................. 9

APPENDIX A: PROJECT BUDGET ESTIMATES

APPENDIX B: REUSE WATER DISTRIBUTION ONE-LINE DIAGRAM

Executive Summary The purpose of this Concept Budget Report is to provide the scope and estimated cost to distribute reuse water from the City of Raleigh on the Centennial Campus of North Carolina State University. Reuse water is highly treated wastewater effluent from wastewater treatment plants that may be used for irrigation, toilet flushing, cooling tower make-up, and other industrial purposes. The City of Raleigh is constructing a citywide reuse water distribution system, which has recently been extended to the Lonnie Poole Golf Course on the Centennial Campus. The connection to the existing Lonnie Poole Golf Course irrigation system will be included in this project. The Centennial Campus reuse water distribution system is to be maintained independently of the Lonnie Poole Golf Course. This report outlines the phasing required in order to construct the reuse system in $500,000 project cost increments. North Carolina State University has selected the Hunt Library, the Centennial Campus Central Utility Plant, and irrigation at The Oval as the first end users of the reuse water system. Future end users will include the future College of Textiles Central Utility Plant and irrigation at Partners I Courtyard, Partners III, Partners II and Toxicology. They also indicated the preferred location for a pump station would be adjacent to the existing Lonnie Poole pump house, with the distribution pipe routed along Main Campus Drive. The Centennial Campus reuse water system is proposed to be constructed in four phases with a total estimated project cost of $1,745,040. The system will require a pumping station to deliver 1100 GPM with 300 feet of head to meet peak demand conditions. The pumping station is proposed to include two 75 HP pumps and one 25 HP pump. The distribution system will include approximately 6540 feet of 10-inch main pipe.

1. Project Overview The City of Raleigh developed a Reuse Water System Master Plan in 2007, which included North Carolina State Universitys Centennial Campus as a major end-user. The City is now completing its distribution extension to the Centennial Campus. The University will be responsible for distribution to its facilities on the Campus. The purpose of this study is to identify the appropriate location and configuration of a pump station, develop an overall cost and define packages that could be constructed in $500,000 increments.

2. Connected Loads Four users of the Centennial Campus reuse water system were identified by North Carolina State University: the Centennial Campus Central Utility Plant, the Hunt Library, irrigation of the Oval, and the future College of Textiles Central Utility Plant. The following table provides a summary of the connected loads. NC State Centennial Campus Reuse Water Loads

Building Elevation

(ft.)

Required Delivery Pressure

(psi)

Peak Flow Rate

(GPM) Peak Period Notes Oval Irrigation 337 75 50 10 PM - 7AM

320' at the bottom, 380' at the top of the Oval

Hunt Library 337 83 50 9 AM - 6 PM

166 GPM w/o diversity; 83psi w/o booster

Centennial CUP 420 10 820 11 AM - 6 PM 340 GPM current; 820 GPM future CoT CUP 340 10 190 11 AM - 6 PM

Based on 5000 Tons per Utility Master Plan

Table 1

2.1 Centennial Campus CUP The Centennial Campus CUP will use reuse water for cooling tower make-up. The current chilled water plant installed capacity is 9,000 Tons. According to the Centennial Campus Utility Master Plan, the planned capacity is 22,000 Tons. At peak load, the make-up water flow required to maintain 6 cycles of concentration is 340 GPM at the current capacity. Once the plant is fully built-out, the required make-up flow will be 820 GPM. Reuse water will be required to be delivered at a minimum pressure of 10 psig. The cooling tower basin elevation is approximately 420 ft. above sea level, which is approximately 160 feet higher than the proposed pump station location. The Centennial Campus CUP will have the highest demand on the reuse water system; however, it will vary with the chiller plant load. Demand is expected to be lowest over night and in the early morning, from 10 PM to 6 AM. Peak consumption is expected to be from 11 AM to 6 PM. The total daily reuse water consumption is expected to be 180,000 gallon per day.

2.2 Hunt Library The recently completed Hunt Library was designed to use reuse water for toilet and urinal flushing. Based on the number of fixtures, the peak flow with diversity is approximately 50

North Carolina State University, Centennial Campus Reuse Water Distribution Concept and Budget Report Page 1

GPM. In order to provide a minimum of 25 psig to the furthest flush valve on the highest floor, reuse water will be required to be delivered at 83 psig at the building entrance point or a booster pump will be required. The Hunt Library is located at 337 ft. above sea level. The reuse water demand will vary with occupancy and is expected to coincide with demand from the central utility plants. The total daily consumption is expected to be 6,000 gallons per day.

2.3 Oval Irrigation The Oval is planned as a large central open green space. The portion surrounded by Engineering Buildings I, II, and III has been constructed. This portion is irrigated using city domestic water. The remaining portion, near the Hunt Library, will use reuse water for irrigation. The peak flow rate is expected to be 50 GPM and will be required to be delivered at a minimum of 75 psig at the point of connection to accommodate rotating spray heads. The elevation of The Oval varies from approximately 320 ft. to 380 ft. above sea level. Irrigation is not expected during occupied hours, but rather is expected to occur from 10 PM to 7 AM. Therefore, this demand is not coincidental with the central utility plants or the Hunt Library. The total daily consumption is expected to be 75,000 gallons per day.

2.4 Future College of Textiles CUP The College of Textiles CUP is planned for the southwest portion of the campus and will use reuse water for cooling tower make-up. The planned chilled water plant capacity is 5,000 Tons. At peak load, the make-up water flow required to maintain 6 cycles of concentration would be 190 GPM at full capacity. Reuse water will be required to be delivered at a minimum pressure of 10 psig. The plant will be located at approximately 340 ft. above sea level. The College of Textiles CUP demand on the reuse water system will vary with the chiller plant load and will be coincident with the Centennial Campus CUP and the Hunt Library demand. Demand is expected to be lowest over night and in the early morning, from 10 PM to 6 AM. Peak consumption is expected to be from 11 AM to 6 PM. The total daily reuse water consumption is expected to be 33,000 gallon per day.

2.5 Future Irrigation Connections Branch piping will be stubbed out to allow connection of existing irrigation systems to the reuse water system. Four locations have been identified: Partners I Courtyard, Partners III, Partners II and Toxicology. The peak flow rate is expected to be 50 GPM each and will be required to be delivered at a minimum of 75 psig at the point of connection. The point of connect for these locations will all be below 380 ft. above sea level. The demand from the irrigation system will depend on how the systems zones are scheduled to operate. Since the irrigation, systems are operated when the campus is unoccupied and the cooling demands are low, the reuse system would have ample capacity for flow. However, the pressure will be dependent on the demand from the cooling towers. With the proposed 10-inch main and 300 ft. head pump station, a total flow 400 GPM and 75 psig can be maintained up to 380 ft. above sea level.


2.6 Demand Summary The peak demand on the reuse water system will be from the simultaneous uses from the Centennial Campus CUP, College of Textiles CUP, and the Hunt Library. The total demand will be 1060 GPM.

Figure 1 Reuse Water System Users

3. Reuse Water Distribution To provide reuse water for irrigation of the Lonnie Poole Golf Course and service to the Centennial Campus, the City of Raleigh is extending a 16-inch reuse water main from Centennial Parkway to the existing irrigation pump house. A separate reuse meter will be provided by the City to serve as a master meter for the Centennial Campus. The Centennial Campus is located in the 595 pressure zone; however, the reuse water tower serving it is located in the 495 pressure zone. It is expected that the City will deliver reuse water at 20-30 psig to the Lonnie Poole pump house, which is located at approximately

Centennial CUP

Hunt Library

The Oval Irrigation

CoT CUP


260 ft. above sea level. The net elevation change from the pump station to the Centennial Campus CUP is approximately 160 feet.

Figure 2 Proposed Pump Station Location

3.1 Pumping Station Due to the lack of pressure from the Citys reuse water main, a pumping station will be required. In order to accommodate the Campus Master Plan, the pumping station will be located adjacent to the Lonnie Poole pump house. At this location, 300 ft. of head pressure will be necessary to provide 10 psig at the Centennial Campus CUP at peak flow. The 300 feet of head accommodates the elevation difference and pipe friction losses. It is recommended that the pumping station be a factory-fabricated pump house skid, in lieu of stick-built construction. The pumping station is proposed to consist of three pumps with variable frequency drives controlled to provide a constant pressure at the Centennial Campus CUP. To accommodate the peak flow conditions, two 75 HP pumps will provide 500 GPM each. A third 25 HP jockey pump is proposed in order to provide enough turndown to accommodate low flow periods. The pumps will be operated in a lead/lag sequence. The total pump station capacity with all pumps in use will be 1100 GPM. A detailed layout of the pump house equipment, similar to Figure 3, will be provided in the design documents. Special attention will be given to provide proper clearance for maintenance and repair of all the equipment. Trolley beams will be provided to assist with pump and motor removal. For aesthetics, the exterior finish is proposed to be painted siding to match the existing Lonnie Poole pump house.

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Existing Lonnie Poole irrigation pump house

Proposed reuse water pump station


Figure 3 Pump Station Layout

3.2 Distribution Piping Reuse water will be distributed via ductile iron piping routed from the pumping station along Main Campus Drive. The distribution main will end at the Centennial Campus CUP, requiring approximately 6540 ft. of main piping. The main distribution piping is proposed to be 10-inch from the pumping station up to the College of Textiles CUP connection near Research Drive and continuing with 10-inch to the Centennial Campus CUP. The piping will be buried within Main Campus Drive under a minimum of 3 feet of cover. This will require trenching and patching of the asphalt and disruption of traffic patterns during construction. To serve the Hunt Library and The Oval irrigation, a 6-inch branch line will be routed east under Partners Way. A 4-inch stub branch to the west will be provided near Research Drive for the future College of Textiles CUP. Locating the pumping station adjacent to the Lonnie Poole pump house will require crossing Walnut Creek with the distribution main. In order for the City to route the 16-inch reuse main line to Lonnie Poole, a jack and bore was required to cross under the creek. According to the Citys water line maps, a 16-inch domestic city water main is routed in Main Campus Drive over the Walnut Creek culvert. For the purposes of this report, it is assumed that a 10-inch reuse main can be routed over the Walnut Creek culvert and a jack and bore will not be required.


Figure 4 City Water Line Map

3.3 Connection Requirements The City of Raleigh will provide one reuse water meter at the point of connection. This will serve as a master meter for all of the Centennial Campus including the Lonnie Poole Golf Course irrigation system. The domestic city water to facilities on the Centennial Campus is individually metered. North Carolina State University has negotiated with the City of Raleigh to be exempt from the requirement to have wastewater meters installed for net metering. In order to allocate the reuse water costs, submeters will be provided at each connection point. Reuse water lines and domestic water lines are not allowed to be interconnected. Where it is desired to have domestic water as a back up, an air gap on the domestic water will be required. For cooling tower make-up, the reuse water may be connected directly to the condenser water piping but domestic water must be routed to the tower basins in order to provide an air gap. In the case of toilet flushing, the reuse water piping may be connected directly to the building. The reuse water within the building may be used for toilet and urinal flushing, but cannot be connected to any hose bibs. If it is desired to use the domestic water supply as a back up to the reuse water, then an air gap will be required. The loss of pressure would necessitate adding a booster pump system after the air gap to provide the required pressure. Where reuse water is used for irrigation, soil testing and annual hydraulic loading calculations may be required for permitting.

4. Project Phasing and Budgets In order to facilitate the procurement process, the project will be phased. The project cost budget will be limited to $500,000 for each phase. The total project cost is estimated to be $1,745,040. The project is proposed to be completed in four phases.


Project Budget Summary Phase 1 $415,800 Phase 2 $415,800 Phase 3 $415,800 Phase 4 $206,800 Total Project Construction Budget $1,454,200 Project Soft Costs $290,840 Total Project Budget $1,745,040

Figure 5 Budget Summary

4.1 Phase One The scope for Phase 1 is proposed to include the installation of the pumping station and connection of the existing Lonnie Poole pump house to the reuse water main. At the end of Phase 1, there will be no connected loads. It is recommended that the pumping station be factory-fabricated. This would allow the pumping station to be factory tested and verified that it will meet the pressure and flow requirements. The estimated cost of construction for Phase 1 is $415,800, with a total project cost of $498,960.

Figure 6 Phase One Scope

4.2 Phase Two The scope for Phase 2 is proposed to extend the distribution piping approximately 3000 feet from the new pumping station to Partners Way. Due to the lack of depth over the pedestrian tunnel, it is assumed that the pipe will be rerouted around the tunnel for estimating purposes. Reduced cover, a shock pad, or other methods to allow routing of the pipe over the pedestrian tunnel will be investigated during the design phase. A tee will be provided for the 6-inch distribution branch to the Hunt Library and The Oval irrigation. At the end of Phase 2, there will be no connected loads. The estimated cost of construction for Phase 2 is $415,800, with a total project cost of $498,960.

Proposed reuse water pump station

10-inch Reuse Water Line

16-inch Reuse Water Line

City Reuse Water Line


Figure 7 Phase Two Scope

4.3 Phase Three The scope for Phase 3 is proposed to extend the distribution piping approximately 2460 feet from the end of Phase 2 to near the Partners II building. A 6-inch distribution branch to the Hunt Library and The Oval irrigation will be included. The Hunt Library will be connected to the reuse water system. This will include a reuse water submeter for the building, and backflow prevention. A pipe pressure sensor will be installed in the Hunt Library to control the reuse water system pumping station installed in Phase One. The Oval irrigation will be disconnected from the city domestic water and connected to the reuse water system. Once the Hunt Library and Oval irrigation connections are made, the pumping station can be placed in operation. The maximum demand at the end of this phase will be 100 GPM, therefore only the 25 HP jockey pump will be needed. Provisions for future connections to the reuse water distribution system will be made. A 4-inch branch stub will be provided near Research Drive for the future College of Textiles CUP. At Partners I Courtyard, Partners III, Partners II and Toxicology, 3-inch branch lines will be stubbed out for future connection to the irrigation systems. The estimated cost of construction for Phase 3 is $415,800, with a total project cost of $498,960.

10-inch main pipe

End of Phase 1

Pedestrian Tunnel


Figure 8 Phase Three Scope

4.4 Phase Four The scope for Phase 4 is proposed to extend the main distribution piping approximately 670 feet from the end of Phase 3. The Centennial Campus CUP will be connected to the reuse water system by approximately 410 feet of 10-inch branch piping. This will include rerouting of the existing make-up water line to provide the required air gap, and revisions to the tower level controls. An additional pipe pressure sensor will be installed in the Centennial Campus CUP to control the pumping station. The estimated cost of construction for Phase 4 is $206,800 with a total project cost of $248,160.

Hunt Library connection

Stub for future connection (4 total)

4-inch stub to CoT CUP

Oval irrigation connection


Figure 9 Phase Four Scope

Centennial CUP connection

End of Phase 3


APPENDIX A

North Carolina State University

Centennial Campus Reuse Water Distribution

Concept and Budget Report

AEI Project No: 13108-00 SUMMARY

SUMMARY

Description Sub-Total

Phase 1 415,800$

Phase 2 415,800$

Phase 3 415,800$

Phase 4 206,800$

TOTAL PROJECT CONSTRUCTION COST BUDGET 1,454,200$

Project Soft Costs 290,840$

TOTAL PROJECT BUDGET 1,745,040$

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AEI Project No: 13108-00 Phase 1

Phase 1

UNIT EXT

LABOR & LABOR &

Description QTY UNIT MATERIAL MATERIAL

Pump Station

Packaged Pump House 1 EA 235,000$ 235,000$

Site Prep 1 LOT 12,000$ 12,000$

Reuse Water Submeter 1 EA 5,800$ 5,800$

Controls 1 LOT 5,000$ 5,000$

Electrical 1 LOT 60,000$ 60,000$

Factory Testing 1 LOT 15,000$ 15,000$

Landscaping 1 LOT 7,500$ 7,500$

Subtotal 340,300$

Lonnie Poole Pump House Connection


Controls 1 LOT 5,000$ 5,000$

Valves 2 EA 3,400$ 6,800$

Subtotal 17,600$

Distribution Piping

16" DIP from Meter to Lonnie Poole Pump House 60 LF 165$ 9,900$

10" DIP to Reuse Pump Station 65 LF 125$ 8,125$

10" DIP from Pump House to Main Campus Dr. 0 LF 125$ -$

10" DIP along Main Campus Dr. 0 LF 125$ -$

Flow and Pressure Testing 1 LOT 2,500$ 2,500$

Subtotal 10,625$

Subtotal 378,000$

Estimating Contingency 10% 37,800$

Construction Cost 415,800$

Project Soft Costs 20% 83,160$

Total 498,960$

Notes:

1. The Project Soft Costs include the following items:

a. Owner reserves for management, fixed equipment or other Owner furnished labor and materials.

b. Reserves for NCSU Agencies/Departments

c. Construction contingencies.

d. Design fees.

e. Permit, review and approval fees for NCDENR, etc.

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Phase 2

UNIT EXT

LABOR & LABOR &


Distribution Piping

10" DIP Main ( from end of Phase 1) 3000 LF 125$ 375,000$


Subtotal 377,500$

Subtotal 378,000$




Total 498,960$

Notes:





d. Design fees.


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Phase 3

UNIT EXT

LABOR & LABOR &


Distribution Piping

10" DIP Main (from end of Phase 2) 2460 LF 125$ 307,500$

10" Valves 1 EA 2,275$ 2,275$

6" DIP (Branch to Hunt Library and Oval) 250 LF 75$ 18,750$

4" DIP (Branch to future CoT CUP) 50 LF 75$ 3,750$

Service Tap 5 EA 1,500$ 7,500$

3" Branch Piping (for future) 100 LF 80$ 8,000$


Subtotal 350,275$

Hunt Library Connection

3" DIP to building connection 220 LF 75$ 16,500$

3" Backflow Preventer 1 EA 2,500$ 2,500$

3" Pressure Reducing Valve 1 EA 2,500$ 2,500$

Piping 50 LF 25$ 1,250$

Controls 1 LOT 2,500$ 2,500$

Reuse Water Submeter 1 EA 500$ 500$

Subtotal 25,750$

Oval Irrigation Connection

2" PVC Piping 30 LF 30$ 900$


Subtotal 1,900$

Subtotal 378,000$




Total 498,960$

Notes:





d. Design fees.


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Phase 4

UNIT EXT

LABOR & LABOR &


Distribution Piping

10" DIP Main (from end of Phase 3) 670 LF 125$ 83,750$

10" Valves 1 EA 2,275$ 2,275$

Service Tap 3 EA 1,500$ 4,500$

2" Branch Piping (for future) 100 LF 80$ 8,000$


Subtotal 101,025$

Centennial Campus CUP Connection

10" Branch piping from main 410 LF 125$ 51,250$ 10" Piping to cooling tower basin 50 LF 125$ 6,250$

Control Valve 1 EA 4,500$ 4,500$

Reroute Cooling Tower Make-up Line (6") 150 LF 79$ 11,850$

Heat Tracing 100 LF 10$ 1,000$

Core Drill 1 EA 1,000$ 1,000$

Controls 1 LOT 5,000$ 5,000$


Subtotal 35,400$

Subtotal 188,000$




Total 248,160$

Notes:





d. Design fees.


4/5/2013 Page 5 of 5

1. Project Overview2. Connected Loads2.1 Centennial Campus CUP2.2 Hunt Library2.3 Oval Irrigation2.4 Future College of Textiles CUP2.5 Future Irrigation Connections2.6 Demand Summary

3. Reuse Water Distribution3.1 Pumping Station3.2 Distribution Piping3.3 Connection Requirements

4. Project Phasing and Budgets4.1 Phase One4.2 Phase Two4.3 Phase Three4.4 Phase Four

ncsu centennial campus reuse water concept report

Documents

centennial campus cup

budget report aei project

distribution piping

project phasing

project overview

concept budget report

demand summary

line diagram executive