toledo collins park wtp 40 mgd plant …...presentation (not behind any of the other layouts,...
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TOLEDO COLLINS PARK WTP 40 MGD PLANT ADDITION DESIGN CONSIDERATIONS AND CHALLENGESKurt Smith, PE & Jack Kane, PE - ARCADIS
Jim Donnell, PE - City of ToledoSeptember 28, 2017
© Arcadis 2017
Purpose:h
20 MGD Redundancy- Allow basin maintenance year round
yt
20 MGD Capacity- Address OEPA significant deficiency
Collins Park WTP – 40 MGD Plant Addition
© Arcadis 2017
Kurt SmithProject Manager
Collins Park WTP – Process Flow Schematic
© Arcadis 2017
DES
IGN
CO
NSI
DER
ATIO
NS
• Pumped rapid mix
• Flocculation
• Sedimentation
• Effluent troughs
• Algae skimmers
• Recarbonation
• Ozone connection
• GAC Filters
CH
ALL
ENG
ES • Tight site constraints• Other contractors• Utility relocations• Security
• Maintenance of plant operations (MOPO)• Interconnections to
existing East Plant
• Preservation of Lagoon E
CO
ST S
AVIN
GS
MEA
SUR
ES • Sedimentation basin size reduction
• 3D CAD benefits• Design• Construction• Post Construction
• Prequalification of contractors
• Low bids
Collins Park WTP – 40 MGD Plant Addition
© Arcadis 2017
VERTICAL RAPID MIXER ALTERNATIVE
RAPID MIX PUMP
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WATER CHAMP RAPID MIX ALTERNATIVE
© Arcadis 2017
PUMPED RAPID MIXING SYSTEM
10” DISCHARGE
12” SUCTION
RAPID MIX PUMP
• Rapid mix pump rated for 2,000 gpm at 37’ head with 30 Hp motor
East Plant
© Arcadis 2017
PUMPED RAPID MIXING SYSTEM• East & West Plant rapid mix channels rated for 80 MGD each
OVER BAFFLE
UNDER BAFFLE
8’ X 15.5’ CHANNEL (TYPICAL)
ALUM FEED
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PUMPED RAPID MIXING SYSTEM• Mixing energy exceeds 10-States Standards G-value of 750 fps/ft
ALUM FEED10” DISCHARGE PIPE
INJECTION DIFFUSER NOZZLE
© Arcadis 2017
PUMPED RAPID MIXING SYSTEM
RAPID MIX PUMP
West Plant
© Arcadis 2017
FLOCCULATION BASINS
10” DISCHARGE PIPE
BASIN 7 FLOC DRIVES
LIME SLURRY SPLITTER BOX
SODA ASH SPLITTER BOX
BASIN 8FLOC BASIN
© Arcadis 2017
FLOCCULATION BASINS
ALUM FEED10” DISCHARGE PIPE
INJECTION DIFFUSER NOZZLE
Basins 1 – 6 Upgrades• Equipment
interchangeable with Basins 7 & 8
© Arcadis 2017
SEDIMENTATION BASINS
10” DISCHARGE PIPE
Basins 1 – 6 Upgrades• Equipment interchangeable
with Basins 7 & 8
SLUDGE CROSS COLLECTOR
SLUDGE DRAGS
© Arcadis 2017
EFFLUENT LAUNDER BUILDING
10” DISCHARGE PIPE
INJECTION DIFFUSER NOZZLE
EFFLUENT SUBMERGED
ORIFICE WEIRS (TYPICAL)
© Arcadis 2017
EFFLUENT LAUNDER BUILDING
10” DISCHARGE PIPE
INJECTION DIFFUSER NOZZLE
FLOATABLES ALGAE SKIMMERS
(TYPICAL)
© Arcadis 2017
RECARBONATION BASINS
10” DISCHARGE PIPE
INJECTION DIFFUSER NOZZLE
CO2 DIFFUSERS(TYPICAL)
© Arcadis 2017
OZONE FACILITY CONNECTION
10” DISCHARGE PIPE
KNOCKOUT WALL FOR OZONE INFLUENT CONDUIT
SETTLED WATER CONDUIT GATES FOR
OZONE EFFLUENT CONDUIT
© Arcadis 2017
GAC Filters
INJECTION DIFFUSER NOZZLE
Filter Media Pilot• 12” Sand
Effective size• 0.45 – 0.55 mm
• 24” GAC Effective size
• 1.0 – 1.2 mm
Underdrains• Leopold XA
– IMS 200 caps
© Arcadis 2017
SITE CONSTRAINTS – OTHER CONTRACTORS• Probable Project Costs
– Basin 7 $ 37,200,000– Basin 8 $ 33,400,000– TOTAL $ 70,600,000
• Schedule Basin 7 & Basin 8
• Operational by April 2020
© Arcadis 2017
SITE CONSTRAINTS – OTHER CONTRACTORS• Probable Project Costs
– Basin 7 $ 37,200,000– Basin 8 $ 33,400,000
• Other Concurrent Projects– CPEU $ 17,000,000
• Schedules Basin 7 & Basin 8
• Operational by April 2020 CPEU
• Operational by Sept. 2018
© Arcadis 2017
SITE CONSTRAINTS – OTHER CONTRACTORS• Probable Project Costs
– Basin 7 $ 37,200,000– Basin 8 $ 33,400,000
• Other Concurrent Projects– CPEU $ 17,000,000– Ozone $ 40,000,000– TOTAL $127,600,000
• Schedules CPEU
• Operational by Sept. 2018 Basin 7 & Basin 8
• Operational by April 2020 Ozone Facility
• Operational by July 2020
© Arcadis 2017
SITE CONSTRAINTS – OTHER CONTRACTORS• Additional Concurrent Projects
CPEU• Operational by Sept. 2018
Basin 7 & Basin 8• Operational by April 2020
Ozone Facility• Operational by July 2020
– Lagoon E Spent Lime Removal• Completion by April 2018
– Maintenance Facility• Completion by December 2018
– Basins 1 – 6 Upgrades• Start Construction Jan. 2020
© Arcadis 2017
SITE CONSTRAINTS – SECURITY & SOLUTIONS
© Arcadis 2017
SITE CONSTRAINTS – SECURITY & SOLUTIONS
© Arcadis 2017
Kurt SmithProject Manager
MAINTENANCE OF PLANT OPERATIONS (MOPO)
© Arcadis 2017
Kurt SmithProject Manager
PRESERVATION OF LAGOON E
© Arcadis 2017
Kurt SmithProject Manager
PRESERVATION OF LAGOON E & UTILITY RELOCATIONS
LIMITS OF EXISTING LAGOON E 2:1 SLOPE STRUCTURAL EMBANKMENT
BASIN 8 50 FEET
© Arcadis 2017
Kurt SmithProject Manager
PRESERVATION OF LAGOON E
EXISTING LAGOON CAPACITY
REDUCED FROM 41.8 MG TO 33 MG
OR 21% REDUCTION
© Arcadis 2017
Kurt SmithProject Manager
SEDIMENTATION BASIN SIZE REDUCTION
SPACE SAVINGS
FOR OZONE FACILITY
• Negotiations with OEPA– Based on historic plant
performance– Based on old design text
books 4 hours without sludge equipment
– Based on conservatism of 10-States Standards
• Cost Savings Benefits– Detention time reduced from
4 hours to 3 hours• ~ $5.8 M savings
– Provides space savings for new Ozone Facility
© Arcadis 2017
Kurt SmithProject Manager
3D CAD BENEFITSDESIGN PHASE- Excellent 3D visualization- Interactive tool with Owner
- Design progress meetings- Freedom Navisworks software (for the novice)
- Clash detection to:- Improve quality of bidding documents- Minimize change orders
- Bidding Phase- Provide to Contractors
© Arcadis 2017
Kurt SmithProject Manager
3D CAD BENEFITS CONSTRUCTION PHASE (CONTRACTOR)
- Quicker orientation of project estimators, managers & trades
- More efficient coordination of trade disciplines to resolves conflicts
- Decreases errors and corrections in field
- Higher reliability of expected field conditions and plan drawings
- Allows for more prefabrication offsite with higher quality and lower cost
- Reduce RFI’s and expedite construction schedule
- Creates a safer workplace
- Construction sequencing
© Arcadis 2017
Kurt SmithProject Manager
3D CAD BENEFITS POST CONSTRUCTION
- Develop 3D views for O&M Manuals
- CMMS (computerized maintenance management system)
- Add asset information to model for O&M/asset management
- Freedom Navisworks software (for the novice)- Interactive tool for operator and safety training
© Arcadis 2017
Kurt SmithProject Manager
PREQUALIFICATION OF CONTRACTORSPrequalification Process- Received 6 proposals- Short listed to 4 Contractors to bid
Evaluation Process- Bonding- Verifiable statement confirming financial wherewithal- Planned approach to the project- References- Construction Experience
- Water/wastewater projects- Large excavation
- Workforce & Workload- Corporate Health, Safety & Environmental Program
Control Quality and Risk Reduction
© Arcadis 2017
Kurt SmithProject Manager
LOW BIDSCONSTRUCTION BID RESULTS
BASIN 7 AND BASIN 8 PROJECTS
Description Basin 7 Basin 8
Engineer’s Estimate $37,740,000 $32,820,000
Average of Bids $36,337,865 $33,319,259
Low Bid $28,387,750 $26,694,200
Cost Below Average of Bids $7,950,115 $6,625,059
% Below Average of Bids 21.9% 19.9%
© Arcadis 2017
Thank you!
© Arcadis 2017
Kurt SmithProject Manager
3D CAD BENEFITS
© Arcadis 2017
DES
IGN
CO
NSI
DER
ATIO
NS
• Pumped rapid mix
• Flocculation
• Sedimentation
• Effluent troughs
• Algae skimmers
• Recarbonation
• Ozone connection
• GAC Filters
CH
ALL
ENG
ES • Tight site constraints• Other contractors• Utility relocations• Security
• Maintenance of plant operations• Interconnections to
existing East Plant
• Preservation of Lagoon E
CO
ST S
AVIN
GS
MEA
SUR
ES • Sedimentation basin size reduction
• 3D CAD benefits• Design• Construction• Post-construction
• Pre-qualification of contractors
• Low bids
Collins Park WTP – 40 MGD Plant Addition
© Arcadis 2017
DES
IGN
CO
NSI
DER
ATIO
NS
• Pumped rapid mix
• Flocculation
• Sedimentation
• Effluent troughs
• Algae skimmers
• Recarbonation
• Ozone connection
• GAC Filters
CH
ALL
ENG
ES • Tight site constraints• Other contractors• Utility relocations• Security
• Maintenance of plant operations• Interconnections to
existing East Plant
• Preservation of Lagoon E
CO
ST S
AVIN
GS
MEA
SUR
ES • Sedimentation basin size reduction
• 3D CAD benefits• Design• Construction• Post-construction
• Pre-qualification of contractors
• Low bids
Collins Park WTP – 40 MGD Plant Addition
© Arcadis 2017
TitleText DESIGN PHASE
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TitleText
© Arcadis 2017
Title
Text
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TitleText
COST SAVINGSSDFD
SDFDSFSDFSDFDSFSDF
© Arcadis 2017
SITE CONSTRAINTS – OTHER CONTRACTORS
• Probable Project Costs– Basin 7 $ 37,200,000– Basin 8 $ 33,400,000
• Other Concurrent Projects– CPEU $ 17,000,000– Ozone $ 40,000,000– TOTAL $127,600,000
• Schedules CPEU
• Operational by Sept. 2018 Basin 7 & Basin 8
• Operational by April 2020
© Arcadis 2017
SITE CONSTRAINTS – OTHER CONTRACTORS
• Schedule Ozone Facility
• Operational by July 2020
• Probable Project Costs– Ozone Facility $37,200,000
© Arcadis 2017
TitleText
© Arcadis 2017
TitleText
© Arcadis 2017
Kurt SmithProject Manager
© Arcadis 2017
Kurt SmithProject Manager
• Probable Project Costs– Basin 7 $48,700,000– Basin 8 $43,400,000– TOTAL $92,100,000
© Arcadis 2017
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