Sugar Creek WWTP – CMAR Project Delivery for · Sugar Creek WWTP – CMAR Project Delivery for Reliability Improvements 2018 NC AWWA WEA Spring Symposium . March, 2018, Asheville

© 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


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


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 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


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


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


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


Photo


LIDAR SCANClearance b/t supports


Outdoors also!

Demolished overhead supports for pump access/maintenance

Proposed – Upper level looking downExisting – Lower level looking up


Existing pump station layout


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


Photo


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


Photo


LIDAR SCAN


BIM compatible

Clearance b/t supports



Photo


LIDAR SCAN


BIM compatible

Clearance b/t supports


Outdoors also!


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



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


Questions?

Documents

Sugar Creek WWTP – CMAR Project Delivery for · Sugar Creek WWTP – CMAR Project Delivery for Reliability Improvements 2018 NC AWWA WEA Spring Symposium . March, 2018, Asheville