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1.0 Executive Summary
1.1 Introduction
The purpose of this 2009 Facilities Master Plan (Master Plan) is to identify the capital
improvement needs of the Orange County Sanitation District (OCSD) through 2030, and to
provide the information needed for planning and budgeting those improvements.
The Master Plan implements the Board-approved Level of Service goals from the OCSD
Strategic Plan.
1.2 Document Organization
This Master Plan is presented in five volumes, organized as follows:
Name Description
Volume 1 - Summary Includes the Table of Contents, Executive Summary, and Project
Summary.
Volume 2 - Treatment Plants Provides a detailed evaluation of the facilities at Plant No. 1 in
Fountain Valley, Plant No. 2 in Huntington Beach, and the North
County Yard.
Volume 3 - Collections System Provides updated information to the 2006 Collections System
Model and Strategic Plan Update.
Volume 4 - Air Quality,
Stormwater, and Biosolids
Management
Describes air quality, odor control, stormwater management, and
biosolids management for the treatment plants and the
collections system.
Volume 5 - Recommendations Includes the cash flow summary, project list, project description
sheets, issue list, and issue descriptions.
1.3 OCSD Overview
OCSD is a regional wastewater agency serving 2.5 million people in central and north
Orange County, California. The 25-member Board of Directors is comprised of one
representative from each of the 21 cities and 3 special districts in the service area, and
one representative from the County Board of Supervisors.
The annual influent flow of 211 million gallons per day (mgd) comes primarily from
11 sewer sheds within the 479-mile service area. OCSD also receives flow from the Santa
Ana Watershed Project Authority (SAWPA) and the Irvine Ranch Water District (IRWD),
and treats urban runoff from within the service area.
Treated wastewater is a major reclamation source in Orange County. The Orange County
Water District (OCWD) Groundwater Recharge System (GWRS) treats OCSD effluent to
drinking water standards for groundwater recharge and irrigation uses. It is the largest
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advanced water purification facility of its kind in the world, serving as a model for global
water recycling.
1.4 History
Previous OCSD planning efforts included the 1989 Master Plan and the 1999 Strategic Plan.
A 2002 Strategic Plan Update was prepared to address the following issues that developed
after the 1999 Strategic Plan.
• Bacterial contamination along the Huntington Beach shoreline.
• Wastewater flows being lower than previously projected.
• Finalization of the OCWD GWRS design.
• Urban runoff treatment needs.
• Bans on the land application of Class “B” biosolids.
• Preparation for renewal of the Ocean Permit.
Prior to 2002, OCSD discharged a blend of both primary and secondary effluent into the
ocean in accordance with a Clean Water Act (CWA) section 301(h) variance. On July 17,
2002, the OCSD Board of Directors decided to withdraw the variance and achieve federal
secondary treatment standards for all ocean discharges. The capital improvements resulting
from this decision and a commitment to increase reclamation initiated a significant
expansion effort. The majority of that work will be completed in 2012.
A primary focus of this 2009 Master Plan was to capture the impact of those changes, and to
plan for the years following the completion of the current expansion effort.
1.5 In-House Effort
The Master Plan was prepared as an internal effort, using staff from various departments.
This highly successful approach provided the following benefits:
• Efficiency: Eliminated staff costs to interface with consultant.
• Flexibility: Without the limitation of the consulting contract, there was more flexibility
to make beneficial scope of work adjustments throughout the process.
• Knowledge Retention: Staff retained the knowledge gained in the process.
• Future Direction: Staff involvement in the Master Plan provided a mutual
understanding of the ongoing issues, a sense of ownership, and a shared vision for the
Capital Improvement Program.
1.6 Planning Assumptions
The future influent flow rate is projected to gradually increase approximately 20 percent
from 2005 through 2030. The main factors that may affect the future flow rate include
population increases, a return to normal rainfall, increased urban runoff treatment, and
increased upstream reclamation.
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1.7 Collections System
1.7.1 Pipelines
The 2006 Strategic Plan Update (2006 SPU) model identified hydraulic capacity concerns in
the regional collections system. The 2009 Master Plan further evaluated those concerns. It
determined that some concerns were less critical than previously believed, and that projects
to address those concerns should be delayed. These recommendations are shown in
Table ES-1.
TABLE ES-1
Truck Sewer, Recommended CIP Project Changes
Project
Number Name
Revised
Date
2-42 Abandon Yorba Linda PS 2020
2-49 SAR_02, Taft Branch 2030
2-72 NHP_01, Rolling Hills Subtrunk
NHP_02, Cypress Ave. Subtrunk and
Newhope-Placentia Trunk
2020
3-55 KNT_01, Westside Relief Intercept/
Los Alamitos MH Rehab
2030
3-59 MLR_01, Miller-Holder Trunk 2030
3-60 KNT_02, Beach Trunk/Knott
Intercept
2017
7-60 HATS_01, Browning Subtrunk 2013
7-62 SUN_01, Von Karman Trunk 2018
11-25 KNT_03, Edinger/Bolsa Chica Trunk 2030
Pipeline rehabilitation needs are currently being evaluated by OCSD staff. Preliminary
findings indicate that many pipelines will require rehabilitation in the near future.
1.7.2 Pump Stations
Pump station and force main capacity needs identified by the 2006 SPU were addressed by
CIP projects, many of which are either in construction or have been completed. Many
pump stations have recently been rehabilitated, replaced, or abandoned. The Master Plan
recommendations for the remaining pump stations address condition and code compliance
concerns.
1.8 Treatment Plant Facilities
As mentioned above, the treatment plants are currently in a period of expansion to increase
reclamation and provide higher levels of treatment. Much of this work will be completed
by 2012.
The primary need in the near future will be to rehabilitate aging infrastructure. Electrical
safety and reliability improvements, and gas compressor rehabilitation are high priorities at
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both plants. Improvements to the supervisory control and data acquisition (SCADA)
systems are needed to address obsolescence and capacity limitations. The Plant No. 1
headworks facility will need major rehabilitation.
1.9 Recommendations
The 2009 Master Plan effort produced a list of over 100 issues related to meeting future
demands, regulatory and policy requirements, rehabilitation needs, and efficiency
opportunities. Many of these issues were developed into CIP project recommendations.
Due to the current expansion efforts, funding for projects identified by the Master Plan will
not be available until after 2012. The cash flow chart in Figure ES-1 shows a gradual
increase in spending after 2012. The projects in the initial years will primarily focus on the
higher-priority rehabilitation needs. The projects planned for future years are associated
with the capacity needs projected for future years.
FIGURE ES-1
Capital Improvement Project Cash Flow
The capital improvement projects recommended by the Master Plan are listed in Table ES-2.
In addition to the capital improvements, various focused studies are needed to clarify other
issues that were identified. These studies are listed in Table ES-3.
A detailed description of each project recommendation is provided in the Master Plan
“Recommendations” (Volume 5).
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TABLE ES-2
Recommended Capital Improvement Projects
Project
Number Name Year Budget
030101 Cypress and NH Placentia Trunks 2020 66,696,574
030102 Seal Beach PS Rehab 2014 14,023,711
030103 Edinger PS Rehab 2014 11,473,945
030104 Bay Bridge PS Rehab 2015 46,851,942
030105 Crystal Cove PS Rehab 2017 7,379,181
030106 MacArthur PS Rehab 2016 7,027,791
030107 Abandon Yorba Linda PS 2020 9,567,403
030108 Lido PS pump replacement 2014 1,291,845
030109 Coyote Hills Golf Course Chem Station 2020 8,610,663
040501 Plant 2, Headworks Cable Tray 2017 *
040502 Plant 1, Headworks Expansion 2025 222,805,742
040602 Plant 1, Primary Treatment, Cable Tray, Odor Ctrl 2016 33,186,816
040701 Plant 1, Secondary Treatment, Cable Tray 2017 *
040703 Plant 2, Secondary Treatment, Cable Tray 2017 *
040802 Plant 1 Flare Addition 2013 2,179,744
040803 Plant 1 Gas Compressor Rehabilitation 2017 28,386,578
040804 Plant 2 Gas Compressor Rehabilitation 2013 23,353,708
040805 Plant 2 Dig. A & B Demo 2013 4,895,550
040806 Plant 2 Gas Holder Demo 2015 993,815
040808 Plant 1, Solids, Cable Tray 2017 *
040810 Plant No.2 Silo Rehabilitation 2018 37,603,782
041201 66" Interplant Effluent Pipeline Rehabilitation 2014 50,038,969
041406 Plant 1, Potable Water System Deficiencies 2010 136,269
041701 Plant 2, New 66kV SCE Feed. 2025 25,947,757
041702 Plant 2, Load Management/Shedding. 2016 18,248,515
041703 Plant 1, Cengen, Cable Tray 2016 *
041802 Plant 2, SWGR Replacement (Dist B, Dist D). 2012 3,237,798
041903 PB-2 Diesel Generator Reinstatement 2014 192,762
042001 Plant 1 & 2 UPS Systems Upgrade. 2015 14,375,774
042101 Plant 2, Independent Process SCADA Network. 2012 9,608,383
042102 VAX Server Migration to Modbus Ethernet 2011 1,145,327
042103 Process SCADA, Modbus Ethernet Redundancy 2011 1,145,327
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TABLE ES-2
Recommended Capital Improvement Projects
Project
Number Name Year Budget
042105 IT Data Storage Addition 2011 444,041
042106 New IT Data Center 2015 2,698,672
042107 New IT Workroom 2012 180,389
042109 Replace Obsolete IT Equipment 2012 12,510,915
042111 IT Systems, North County Yard Bus. Site 2011 666,061
042112 Process SCADA Replacement 2012 22,241,627
042113 Radio Replacement 2012 2,083,725
042201 Lab Piping Replacement 2010 1,114,403
P1-105 Headworks Rehab/Expansion at Plant 1 (Adjust) 2014 15,466,031
Note:
* Cable Tray project, budget will be transferred from Project J-47.
TABLE ES-3
Recommended Studies
Project
Number Name Year Cost
040401 Climate Change Impact Study 2010 81,113
040702 Plant 2, 54-inch PE BFV Study 2009 25,750
040801 Digester Gas Facilities Assessment 2009 103,000
040807 Plant 1 Holders 5&6 Conversion to Digesters 2012 119,235
040809 Plant 2, Soil Liquifaction Study 2013 250,394
040901 Plant 1 and 2 Sidestream Eval 2011 170,336
040902 Plant 2, WSSPS 2A Motor Study 2012 29,809
041001 Effluent Disinfection Study 2011 113,558
041102 Ocean Outfall Easement Renewal 2009 25,750
041103 EPSA Cooling Water Bypass/Override 2010 27,038
041104 Access to SAR flap gates 2012 11,924
041202 66" Interplant Effluent Pipeline Feasibility 2011 11,356
041301 Wastehauler Odor Control Study 2009 103,000
041302 Food Waste Collection and Treatment Study 2012 119,235
041401 Utility Water Systems Study 2010 486,675
041402 Plant 2, Effluent Reuse Study 2012 59,618
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TABLE ES-3
Recommended Studies
Project
Number Name Year Cost
041404 Potable Water Quality Study 2011 56,779
041501 Plant 1 & 2, Plant Air System Master Plan 2010 216,300
041804 Plant 1 & 2, Electrical System Base Map. 2010 216,300
041901 Plants Nos. 1&2 Standby Power Study. 2011 85,168
041902 Outage Recovery Plan 2012 119,235
042002 Plant 1 & 2 UPS Systems Study. 2010 108,150
042104 Process SCADA Link to Pump Stations 2011 102,202
042202 Plant 1 & 2, Admin Facilities Master Plan 2010 270,375
042203 Plant 1 & 2, Uniform Level of Service Stds 2010 81,113
042204 Plant 1 & 2, Roof Rehabilitation 2009 77,250
042205 Plant 1 & 2, Civil Assets Assess 2010 5,407,500
042401 Plant 1 & 2, Hydraulic Study 2012 298,088
050101 Odor Control Master Plan 2012 2,384,708
090101 Stormwater Flow Study 2012 298,088
102010 2010 Future Misc Studies 2010 216,300
102011 2011 Future Misc Studies 2011 227,115
102012 2012 Future Misc Studies 2012 238,471
102013 2013 Future Misc Studies 2013 250,394
102014 2014 Future Misc Studies 2014 262,914
100101 Rate Study 2010 54,075