SOUTH FORK IMPROVEMENTS PROGRAM – A MID-PROGRAM REPORT

Kent A. Lackey, P.E. – Black & Veatch Project Manager

NC AWWA-WEA 95TH ANNUAL CONFERENCE

AGENDA

• BACKGROUND• PROGRAM OVERVIEW• PROGRAM STATUS• EARLY SUCCESSES

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• Winston-Salem/Forsyth County Utility Commission• Approximately 122,000 customers (3rd largest in NC)• 2 WWTPS

• Muddy Creek • 21 mgd capacity

• Archie Elledge• 30 mgd capacity

• Three Drainage Basins• South Fork• Muddy Creek• Elledge

• 49 WW Lift Stations• 1,723 miles of sewer

BACKGROUND – WASTEWATER SYSTEM

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Archie Elledge WWTP

Muddy Creek WWTP

• introductions

BACKGROUND – LONG TERM WASTEWATER TREATMENT ANALYSIS

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Archie Elledge WWTP

Muddy Creek WWTP

Muddy Creek Basin

South Fork Basin

Elledge Basin

South Fork PSNew MC

Transfer PS

• Where is it being generated?

• Convey all flows to plants using existing infrastructure

• Transfer flows between plants

• Transfer flows between basins

• System Equalization• Scalping within the

collection system• Future New Plant

Future Plant Option 1

Future Plant Option 1

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• Program Owner : CCUC• Utilities Administration• Wastewater Treatment• Collection & Maintenance• Finance• City Attorney

• Program Manager: Black & Veatch• Program Management• MCCIPS and Force Main Design• Optimization Study/Design• Funding Assistance• Regulatory Permitting

• Program Consultants:• Hazen and Sawyer: Interceptor

Design/EA• Highfill Infrastructure: Kerner’s Mill

Design• Southeastern Electrical Consultants:

Kerner’s Mill PS Design• Carolina Ecosystems: Environmental

Field Support• Hydromax USA: Pipeline Inspection• Allied Associates: Surveying• Sanborn: Aerial Topography• S&ME: Geotechnical• Clemson Engineering Hydraulics:

Physical Modeling

SOUTH FORK IMPROVEMENTS PROGRAMPROGRAM PARTNERS

SOUTH FORK IMPROVEMENTS PROGRAMOVERVIEW

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South Fork InterceptorsDesign Lead: Hazen and Sawyer

Kerner’s Mill PS and Force MainDesign Lead: Highfill

MCCIPS and Force MainAEWWTP Equalization FacilitiesAEWWTP Aeration Upgrades(New)MCWWTP Power Generation Upgrades(New)Design Lead: Black & Veatch

Linville Springs & Wexford PSDesign Lead: CCUC

SSES ProjectsDesign Lead: Several

• Study Completed in 2013-2014• Aeration/DO Evaluation• Gas Utilization Evaluation• Sidestream Treatment Evaluation for

N and P• Chlorine Control• Performance Management System

• Energy Management Via Ammonia Control

• Interplant Pumping Control System

• Result: AEWWTP Aeration Upgrade and Power Generation Projects Initiated

GENERAL PROGRAM STATUSPROJECT UPDATE – OPTIMIZATION STUDY

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• Additional Program Projects• Process and Energy Optimization Study for AEWWTP and MCWWTP • Program Funding

• Program Funding Application and Administration for State Revolving Fund Loan

• Federal Funding Screening and Application for all 2014 CIP projects

• Other Projects Added to the Program• AEWWTP Equalization Facilities• AEWWTP Aeration Improvements• MCWWTP Power Generation Upgrades• MCWWTP Blower Upgrades Funding

SOUTH FORK PROGRAM PROJECTS

Program is currently approximately $8M under budget

• Current Anticipated Program Construction Cost: $98,320,000

• MCWWTP CIPI: $51,060,000• MCWWTP Transfer Force Main: $4,850,000• AEWWTP Day Tanks: $9,000,000• AEWWTP Aeration System: $4,700,000• South Fork Interceptor Contract 1: $12,550,000• South Fork Interceptor Contract 2: $5,360,000 (estimated)• Kerner’s Mill Force Main: $3,200,000 (estimated)• Kerner’s Mill Pump Station Upgrade: $1,600,000 (estimated)

• MCWWTP Power Generation: $6,000,000 (estimated)

PROGRAM FINANCIAL UPDATEPROGRAM BUDGET - CONSTRUCTION

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• SRF CS370399-08• $70,500,000 Loan Granted (2% rate) • Funds MCCIPS, Force Main, AEWWTP Equalization

• SRF CS370399-09• $9,399,200 Loan Granted (2% rate)• Funds SSES Projects: Peters Creek, 21st Street, Ardmore Basin No. 1

• SRF CS370399-10• $1,079,400 Loan Granted (0% rate)• Funds AEWWTP Aeration System Upgrade

• SRF CS370399-11• $6,003,772 Loan Granted (0% rate)• Funds MCWWTP Power Generation Facilities

• Future Application• MCWWTP Blower Replacement• South Fork Interceptors

GENERAL FINANCIAL UPDATEPROGRAM FUNDING

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• Red text indicates projects currently in construction

PROGRAM SCHEDULE UPDATE

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Project Design Completion

Construction Start

Final Completion

MCCIPS Complete 1/28/15 5/31/17MCCIPS Force Main Complete 6/15/15 8/16/16AEWWTP Equalization System Complete 6/25/15 11/17/16AEWWTP Aeration Upgrades Complete 9/1/15 5/27/16MCWWTP Power Generation 10/31/15 2/2016 2/2017Kerner’s Mill Force Main Complete 1/2016 8/2016Kerner’s Mill Pump Station Upgrade Complete 2/2017 2/2018

South Fork Interceptor Contract 1 Complete 7/15/15 12/16/16South Fork Interceptor Contract 2 Complete 11/2015 11/2016

• Muddy Creek WWTP Consolidated Influent Pumping Station

• 82 mgd Influent PS• Expandable to 138 mgd

• Screening/Grit Removal• 9.5 mgd Transfer PS & 30” Force Main

• Expandable to 30 mgd• Odor Control• 2 - 1 MG Day Tanks• 2 – 3.9 MG Storm EQ Basins• Electrical Switchgear Replacement• NPW Pump Replacement• Demolition of Exist Primary Treatment

and Influent PS• Ferric Chloride Storage/Feed

GENERAL PROGRAM STATUSPROJECT UPDATE - MCCIPS

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GENERAL PROGRAM STATUSPROJECT UPDATE - MCCIPS

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• Elledge WWTP Equalization• Objective:

• Combine AEWWTP and MCWWTP Flows and Equalize Diurnal Variation

• 2 – 2.0 MG Day Tanks w/ Vertical Mixers• Rate Control Structure

• Elledge Aeration Upgrades• Objective:

• Segment Aeration Basins into 4 independent DO Control Zones

• Results:• Reduce air requirements by 7,300 scfm• Approximate Power Savings:

$186,000/yr • Approximate 3-4 yr payback

GENERAL PROGRAM STATUSPROJECT UPDATE – AEWWTP

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• MCWWTP Power Generation• 1 - 1.1 MW Dual Fuel Engine

Generator• Self Enclosed Outdoor Unit• 800kW Capacity on Digester Gas• 1.1 MW Emergency Capacity on

Natural Gas• Power Supplied to Grid

• Digester Gas• Cleaning: particulates, moisture,

H2S• Compressor via Blowers

• Waste Heat• Hot Water for Digester Heating

• Approximately 8 yr payback

GENERAL PROGRAM STATUS PROJECT UPDATE – MCWWTP POWER GENERATION

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• Contract 1• 23,900 LF of 54” pipe• Pipe Material: FRP with

DIP at road crossings

• Contract 2• 8,860 LF of 15-42” pipe• Pipe Material: FRP (42”),

DIP (42”), Clay (15”/18”)

GENERAL PROGRAM STATUSPROJECT UPDATE – INTERCEPTORS

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• Pumping System Final Capacity Refined at 30% Design • Reduced due to Muddy Creek Basin Master Plan and

South Fork Basin Refinement

• Reduce PS Cost and Deferred Initial Equipment (Approx. $1M)

• No Impact to Aggressive Schedule for South Fork Basin Improvements

SOUTH FORK PROGRAM EARLY SUCCESSES

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Basin5 yr Storm Peak Flow (mgd)

Initial 2041 Flows Final 2041 Flows

Muddy Creek Basin 110(Assume 3.4 PF) 92.9

South Fork Basin 40 35.6

Davidson County 1.5 10.0

Total 171 138.5

Program Manager was Able to Make Effective, Ongoing Decisions Based on Collective Information

• Two significant Program Interceptor Projects were Deferred ($11M)• South Fork Basin MP Re-calibration Efforts

Completed and Assessed Before Detailed Design Commenced• Reduced Program Construction and Engineering Cost• No Impact to Aggressive Schedule for South

Fork Basin Improvements

SOUTH FORK PROGRAM EARLY SUCCESSES

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Projects Deferred

CONSOLIDATED INDUSTRIAL ALLOCATION TRACKING

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Muddy Creek WWTP

Archie Elledge WWTP

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Transfer Force Main

SOUTH FORK PROGRAM EARLY SUCCESSES

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• The Program Team is Driving Effective and Open Collaboration• Multiple Projects

• MCWWTP Clarifier Improvements Project• Collection System Master Plan Project• South Fork Program

• Multiple Engineering Firms Provide Collective Decision Making• Winston-Salem• Black & Veatch• Hazen & Sawyer• Highfill Infrastructure Engineering

• Winston-Salem is Benefiting from Collective Expertise and Effective Collaboration

SOUTH FORK PROGRAM EARLY SUCCESSES

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• Benefiting from Effective Collaboration• Exchanged Scope Between MCWWTP Clarifier Improvements Project

and Program Project• Deferred Sitework to Program; • Moved Clarifier Splitter Structure to Clarifier Project

• Evaluating and Coordinating Project Sequencing• Interceptor Designers Considered “Replace in-place” concept to

avoid considerable rock removal along alignment• Program Manager Evaluated Interceptor Sections and Impact

on MCWWTP Flows• Evaluated Early Milestones in PS Project to Incorporate Higher

Influent Flows to Allow full “replace in-place” Without Delay to Program Completion

SOUTH FORK PROGRAM EARLY SUCCESSES

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• Significant Benefits in Bidding and Construction• Significant Contractor interest including in some cases 15 bidders for

a project.• Consolidated and coordinated construction administration efforts• Consolidated database for construction documents and records to

keep things organized for CCUC

CONCLUSIONS

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• Unique Program Management Approach Has Created Value for CCUC• Allows for Expediting Relief of South Fork Basin While

Concurrent Projects are Completed• Allowed to Initiate Projects without “Final” design criteria in

order to Expedite Completion• Consolidated “like” Efforts Increasing Efficiency and Reducing

Cost• Greatly Reduced CCUC Staff Requirements for a Complex set of

Projects• Single Point of Responsibility with a High Level of Collaboration

Between Team Members – Increasing Quality and Value.

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