sludge dewatering and odor control at plant no. 1 …

SLUDGE 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

• Replace aging solids handling odor control

• Rehabilitate storage and truck loadout facility

Project Scope

Plant No. 1PRIMARY CLARIFIER

SECONDARY CLARIFIER

DIGESTERCAKE

STORAGECAKE

LOADOUT

DISSOLVED AIR FLOTATION

THICKENERS

BELT FILTER PRESSES

PRIMARY CLARIFIER

THICKENINGCENTRIFUGE

SECONDARY CLARIFIER

DIGESTER CAKESTORAGE

CAKE LOADOUT

DEWATERNGCENTRIFUGE

Before P1-100 & P1-101 Projects

After P1-100 & P1-101 ProjectsReplacement

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

Current Progress

• Rigorous testing procedure• Comprehensive commissioning plans required

Testing & Commissioning Process

Contractor

OCSD

QA/QC During Installation

Operational Readiness Test (ORT)

Functional Acceptance Test (FAT)

Reliability Acceptance Test (RAT)

Performance Acceptance Test (PAT)

Contractor & OCSD

Centrifuge FacilityFacility SystemsBridge Crane Industrial Water Booster PumpsFiber Optic & PLC’s Electrical Foul Air Collection Drainage & Slot Pumps Power Building 2 HVAC Fire Alarm Security Water Softener System

Chemical & Odor Control SystemsCentrateBleach Facility Pumps A&D Bleach Facility Pumps B&C Sludge Feed Caustic Soda Bulk Storage & Feed Sulfuric Acid Bulk Storage & Feed Odor Control SystemTrickling Filter Pumps Station, including

pumps and valves

Centrifuge Facility Bulk Storage Polymer Dewatering CentrifugesThickening CentrifugesThickened Sludge Transfer SystemBlend TanksSludge Cake TransferSludge Cake ConveyanceDewatering - Mix, Age & Feed Polymer

SystemThickening - 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

SeepexPumps

Security System

Fire Alarm System

Feed Pumps

Sprinkler

HVAC

Fire Suppression

Blend Tanks

Centrate

Odor Control

Polymer

Utilities System

Sludge Feed

Piston Pumps

Fire Alarm System Integration



SeepexPumps

Security System

Fire Alarm System

Feed Pumps

Sprinkler

HVAC

Fire Suppression

Blend Tanks

Centrate

Odor Control

Polymer

Utilities System

Sludge Feed

Piston Pumps

Dewatering System Integration



SeepexPumps

Security System

Fire Alarm System

Feed Pumps

Sprinkler

HVAC

Fire Suppression

Blend Tanks

Centrate

Odor Control

Polymer

Utilities System

Sludge Feed

Piston Pumps

Thickening System Integration



SeepexPumps

Security System

Fire Alarm System

Feed Pumps

Sprinkler

HVAC

Fire Suppression

Blend Tanks

Centrate

Odor Control

Polymer

Utilities System

Sludge Feed

Piston Pumps

Network Communication Block Diagram

Crisp Servers

Thickening & Dewatering Fiber

Cabinet

Blower Building 1 Network Panel

Network Panel

Digester control Room Network

PanelSolids Handling Truck Loading

Network Panel

Truck Loading Console

Emergency Truck Loading Console

Solids Handling Truck Loading PLC

Panel

Truck Loading RIO Panel 1






Truck Loading RIO Panel

Thickening & Dewatering

Network Cabinet

Solids Handling (SH)

SH Monitor PLC Panel

Power Monitor RIO

panel

SH Thickening PLC

he

Thickening RIO 1

Thickening RIO 2

Thickening RIO 3

SH Centrifuge Thickening

Centrifuge PLC 1

Centrifuge PLC 2

Centrifuge PLC 3

SH Dewatering

PLC

Dewatering RIO 1

Dewatering RIO 2

Dewatering RIO 3

SH Centrifuge Dewatering

Gateway

Centrifuge PLC 1

Centrifuge PLC 2

Centrifuge PLC 3

Solids Scrubber

Facilities PLC Panel

Scrubber RIO 1

Scrubber RIO 2

Scrubber RIO 3

SH Utilities PLC Panel

Utility RIO 1 Utility RIO 2 Utility RIO 3

SH Polymer PLC Panel

Polymer RIO 1 Polymer RIO 2 Polymer RIO 3

Cake Piston Pump PLC

Panel

Pump LC Panel 1

Pump LC Panel 2

Pump LC Panel 3


Crisp Servers


Cabinet


Network Panel



Network Panel




Panel









Network Cabinet



Power Monitor RIO

panel

SH Thickening PLC

he

Thickening RIO 1

Thickening RIO 2

Thickening RIO 3


Centrifuge PLC 1

Centrifuge PLC 2

Centrifuge PLC 3

SH Dewatering

PLC

Dewatering RIO 1

Dewatering RIO 2

Dewatering RIO 3


Gateway

Centrifuge PLC 1

Centrifuge PLC 2

Centrifuge PLC 3

Solids Scrubber


Scrubber RIO 1

Scrubber RIO 2

Scrubber RIO 3






Panel

Pump LC Panel 1

Pump LC Panel 2

Pump LC Panel 3

Panels needed for Testing:• Centrate Pumps & Blend Tanks• Thickening Centrifuges & Polymer Feed


Crisp Servers


Cabinet


Network Panel



Network Panel




Panel









Network Cabinet



Power Monitor RIO

panel

SH Thickening PLC

he

Thickening RIO 1

Thickening RIO 2

Thickening RIO 3


Centrifuge PLC 1

Centrifuge PLC 2

Centrifuge PLC 3

SH Dewatering

PLC

Dewatering RIO 1

Dewatering RIO 2

Dewatering RIO 3


Gateway

Centrifuge PLC 1

Centrifuge PLC 2

Centrifuge PLC 3

Solids Scrubber


Scrubber RIO 1

Scrubber RIO 2

Scrubber RIO 3






Panel

Pump LC Panel 1

Pump LC Panel 2

Pump LC Panel 3

Panels needed for Testing:• Centrate Pumps & Blend Tanks• Thickening Centrifuges & Polymer Feed• Dewatering Centrifuges & Polymer Feed• Dewatering Sludge Cake Transfer

• Non-compensable Delays:

• Shared / Compensable Delays:

Schedule Delays

Relocation of Gas Lines 139 days

Silos 1 and 3 piston pump programming delays 208 days

Additional Commissioning Time 163 daysTOTAL 510 days

Delay to Commissioning Silos 1 & 3 132 daysResolution of all Impacts & Implementation of Completion Schedule

384 days

TOTAL 516 days

Schedule Delays2013 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

April 2018 384 163

Legend

= Relocation of Gas Lines

= Silos 1 and 3 piston pump programming delays

= Delay to Commissioning Silos 1 & 3

= Resolution of all other Impacts and Implementation of Completion Schedule

= Additional Commissioning Time

Schedule UpdateProjection in

July 2017Current

Projection

Start Commissioning Mar 2018 Mar 2018 (A)

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

Truck Loading Thickening & Dewatering Systems

Demo of Existing Facilities

Rehabilitation of Silos & Construction of Secondary Truck

Loading (Mostly Complete)

Permanent Truck Loading & Dewatering System

Demolition of Existing Facilities & Completion of Thickening

System

Original Sequence

Current Sequence

• HVAC & Fire Alarm System– Finalizing design & working with FVFD

• Permanent Truck Loading– Working with Operations on options

• Potential issues during commissioning– Performing additional pre-testing– Daily commissioning and twice-weekly

management meetings

Schedule Risks & Mitigation Measures

• 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

Questions?

sludge dewatering and odor control at plant no. 1 …

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