sludge dewatering and odor control at plant no. 1 …
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PowerPoint PresentationSLUDGE DEWATERING AND ODOR CONTROL AT PLANT
NO. 1 PROJECT P1-101
Operations Committee June 6, 2018
• Construct new sludge thickening facilities
• Replace aging dewatering facilities
Project Scope
SECONDARY CLARIFIER
DIGESTER CAKE
STORAGE CAKE
Replacement Rehabilitation
• Construction 97% complete • Structural and mechanical work complete • Rehabilitation of solids storage silos is complete • Rehabilitation of truck loadout facility is ongoing • Final electrical terminations are ongoing • Testing/commissioning of dewatering system is
ongoing • Testing/commissioning of thickening and truck
loading systems to follow
Testing & Commissioning Process
Contractor & OCSD
Centrifuge Facility Facility Systems Bridge Crane Industrial Water Booster Pumps Fiber Optic & PLC’s Electrical Foul Air Collection Drainage & Slot Pumps Power Building 2 HVAC Fire Alarm Security Water Softener System
Chemical & Odor Control Systems Centrate Bleach Facility Pumps A&D Bleach Facility Pumps B&C Sludge Feed Caustic Soda Bulk Storage & Feed Sulfuric Acid Bulk Storage & Feed Odor Control System Trickling Filter Pumps Station, including
pumps and valves
System Thickening - Mix, Age & Feed Polymer
System
LEGEND: - FAT complete - ORT is ongoing - Installation is complete or nearing completion
Truck Loadout System • Phased work to avoid impact to Operations
Rehabilitate Silos 1 & 3
Construct Secondary Load Out
Rehabilitate Silos 2 & 4
Complete Rehab of Permanent Truck Loadout
SYSTEMS: • Silo Foul Air Collection System • Piston Pumps • Silos 1 & 3 • Silos 2 & 4 • Secondary Loadout Fiber Optic,
PLC’s & Electrical • Secondary Truck Loadout Silo Foul
Air Collection System • Secondary Truck Loadout • Permanent Loadout Fiber Optic,
PLC’s & Electrical • New Scale & Permanent Loadout
LEGEND: - FAT complete - ORT is ongoing - Installation is complete or nearing completion - Cannot start until Secondary Loadout is complete
• Most complex project at the Sanitation District • Communication / alteration of live systems • Integration with complex vendor systems • Optimization for Operation and Maintenance • Interconnections of multiple systems
Project Challenges
System Integration
Dewatering Centrifuges
Thickening Centrifuges
Seepex Pumps
Security System
Network Panel
Network Panel
Panel
Truck Loading RIO Panel
SH Polymer PLC Panel
Cake Piston Pump PLC
Network Panel
Network Panel
Panel
Truck Loading RIO Panel
SH Polymer PLC Panel
Cake Piston Pump PLC
Panels needed for Testing: • Centrate Pumps & Blend Tanks • Thickening Centrifuges & Polymer Feed
Network Communication Block Diagram
Network Panel
Network Panel
Panel
Truck Loading RIO Panel
SH Polymer PLC Panel
Cake Piston Pump PLC
Panels needed for Testing: • Centrate Pumps & Blend Tanks • Thickening Centrifuges & Polymer Feed • Dewatering Centrifuges & Polymer Feed • Dewatering Sludge Cake Transfer
• Non-compensable Delays:
Silos 1 and 3 piston pump programming delays 208 days
Additional Commissioning Time 163 days TOTAL 510 days
Delay to Commissioning Silos 1 & 3 132 days Resolution of all Impacts & Implementation of Completion Schedule
384 days
Schedule Delays 2013 2014 2015 2016 2017 2018 2019 2020
NTP January 2013 - Baseline Schedule Duration of 1425 days
January 2015 139
October 2015 208
May 2016 132
= Delay to Commissioning Silos 1 & 3
= Resolution of all other Impacts and Implementation of Completion Schedule
= Additional Commissioning Time
Dewatering Centrifuges Feb 2019 April 2019
Thickening Centrifuges Jun 2019 Nov 2019
Demolition Complete Jun 2019 Nov 2019
• Mitigation Measures – Management Oversight Committee meeting twice per week – Developed completion schedule – Weekly schedule workshops – Streamlined commissioning procedures – Sequence commissioning of the dewatering system first
Sequence
Demo of Existing Facilities
Loading (Mostly Complete)
Demolition of Existing Facilities & Completion of Thickening
System
• Permanent Truck Loading – Working with Operations on options
• Potential issues during commissioning – Performing additional pre-testing – Daily commissioning and twice-weekly
management meetings
• Original Contract Duration was underestimated – Develop a realistic completion schedule
• Piston pump change early in construction – Vendor design integration – Change to programming and cable & conduit schedule
• Secondary Truck Loadout – Temporary facility requiring unanticipated functionality
• Specification/Coordination of Vendor Packages – Control systems requiring detailed coordination – Review specification to limit variables
Lessons Learned
• Approve a contingency increase of $5,076,400 (4.0%) to the construction contract with W.M. Lyles Company for Sludge Dewatering and Odor Control at Plant No. 1, Project No. P1-101, for a total contingency of $14,594,400 (11.5%).
Recommended Action
Operations Committee June 6, 2018
• Construct new sludge thickening facilities
• Replace aging dewatering facilities
Project Scope
SECONDARY CLARIFIER
DIGESTER CAKE
STORAGE CAKE
Replacement Rehabilitation
• Construction 97% complete • Structural and mechanical work complete • Rehabilitation of solids storage silos is complete • Rehabilitation of truck loadout facility is ongoing • Final electrical terminations are ongoing • Testing/commissioning of dewatering system is
ongoing • Testing/commissioning of thickening and truck
loading systems to follow
Testing & Commissioning Process
Contractor & OCSD
Centrifuge Facility Facility Systems Bridge Crane Industrial Water Booster Pumps Fiber Optic & PLC’s Electrical Foul Air Collection Drainage & Slot Pumps Power Building 2 HVAC Fire Alarm Security Water Softener System
Chemical & Odor Control Systems Centrate Bleach Facility Pumps A&D Bleach Facility Pumps B&C Sludge Feed Caustic Soda Bulk Storage & Feed Sulfuric Acid Bulk Storage & Feed Odor Control System Trickling Filter Pumps Station, including
pumps and valves
System Thickening - Mix, Age & Feed Polymer
System
LEGEND: - FAT complete - ORT is ongoing - Installation is complete or nearing completion
Truck Loadout System • Phased work to avoid impact to Operations
Rehabilitate Silos 1 & 3
Construct Secondary Load Out
Rehabilitate Silos 2 & 4
Complete Rehab of Permanent Truck Loadout
SYSTEMS: • Silo Foul Air Collection System • Piston Pumps • Silos 1 & 3 • Silos 2 & 4 • Secondary Loadout Fiber Optic,
PLC’s & Electrical • Secondary Truck Loadout Silo Foul
Air Collection System • Secondary Truck Loadout • Permanent Loadout Fiber Optic,
PLC’s & Electrical • New Scale & Permanent Loadout
LEGEND: - FAT complete - ORT is ongoing - Installation is complete or nearing completion - Cannot start until Secondary Loadout is complete
• Most complex project at the Sanitation District • Communication / alteration of live systems • Integration with complex vendor systems • Optimization for Operation and Maintenance • Interconnections of multiple systems
Project Challenges
System Integration
Dewatering Centrifuges
Thickening Centrifuges
Seepex Pumps
Security System
Network Panel
Network Panel
Panel
Truck Loading RIO Panel
SH Polymer PLC Panel
Cake Piston Pump PLC
Network Panel
Network Panel
Panel
Truck Loading RIO Panel
SH Polymer PLC Panel
Cake Piston Pump PLC
Panels needed for Testing: • Centrate Pumps & Blend Tanks • Thickening Centrifuges & Polymer Feed
Network Communication Block Diagram
Network Panel
Network Panel
Panel
Truck Loading RIO Panel
SH Polymer PLC Panel
Cake Piston Pump PLC
Panels needed for Testing: • Centrate Pumps & Blend Tanks • Thickening Centrifuges & Polymer Feed • Dewatering Centrifuges & Polymer Feed • Dewatering Sludge Cake Transfer
• Non-compensable Delays:
Silos 1 and 3 piston pump programming delays 208 days
Additional Commissioning Time 163 days TOTAL 510 days
Delay to Commissioning Silos 1 & 3 132 days Resolution of all Impacts & Implementation of Completion Schedule
384 days
Schedule Delays 2013 2014 2015 2016 2017 2018 2019 2020
NTP January 2013 - Baseline Schedule Duration of 1425 days
January 2015 139
October 2015 208
May 2016 132
= Delay to Commissioning Silos 1 & 3
= Resolution of all other Impacts and Implementation of Completion Schedule
= Additional Commissioning Time
Dewatering Centrifuges Feb 2019 April 2019
Thickening Centrifuges Jun 2019 Nov 2019
Demolition Complete Jun 2019 Nov 2019
• Mitigation Measures – Management Oversight Committee meeting twice per week – Developed completion schedule – Weekly schedule workshops – Streamlined commissioning procedures – Sequence commissioning of the dewatering system first
Sequence
Demo of Existing Facilities
Loading (Mostly Complete)
Demolition of Existing Facilities & Completion of Thickening
System
• Permanent Truck Loading – Working with Operations on options
• Potential issues during commissioning – Performing additional pre-testing – Daily commissioning and twice-weekly
management meetings
• Original Contract Duration was underestimated – Develop a realistic completion schedule
• Piston pump change early in construction – Vendor design integration – Change to programming and cable & conduit schedule
• Secondary Truck Loadout – Temporary facility requiring unanticipated functionality
• Specification/Coordination of Vendor Packages – Control systems requiring detailed coordination – Review specification to limit variables
Lessons Learned
• Approve a contingency increase of $5,076,400 (4.0%) to the construction contract with W.M. Lyles Company for Sludge Dewatering and Odor Control at Plant No. 1, Project No. P1-101, for a total contingency of $14,594,400 (11.5%).
Recommended Action