HomeMy WebLinkAboutItem 12 PPP 06-06-18 Operations Committee - P1-101 Contingency Increase.pdfSLUDGE 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. 1
PRIMARY
CLARIFIER
SECONDARY
CLARIFIER
DIGESTER
CAKE
STORAGE CAKE
LOADOUT
DISSOLVED AIR
FLOTATION
THICKENERS
BELT FILTER
PRESSES
PRIMARY CLARIFIER
THICKENING
CENTRIFUGE
SECONDARY
CLARIFIER
DIGESTER CAKE
STORAGE CAKE
LOADOUT
DEWATERNG
CENTRIFUGE
Before P1-100 & P1-101 Projects
After P1-100 & P1-101 Projects
Replacement
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 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
Centrifuge Facility
Bulk Storage Polymer
Dewatering Centrifuges
Thickening Centrifuges
Thickened Sludge Transfer System
Blend Tanks
Sludge Cake Transfer
Sludge Cake Conveyance
Dewatering -Mix, Age & Feed Polymer 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
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
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
Dewatering 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
Thickening 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
Network Communication Block Diagram
Crisp Servers
Thickening & Dewatering Fiber Cabinet
Blower Building 1 Network Panel
Network Panel
Digester control Room Network Panel Solids 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 2 Truck Loading RIO Panel 3 Truck Loading RIO Panel 4 Truck Loading RIO Panel 5 Truck Loading RIO Panel 6
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
Network Communication Block Diagram
Crisp Servers
Thickening & Dewatering Fiber Cabinet
Blower Building 1 Network Panel
Network Panel
Digester control Room Network Panel Solids 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 2 Truck Loading RIO Panel 3 Truck Loading RIO Panel 4 Truck Loading RIO Panel 5 Truck Loading RIO Panel 6
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
Panels needed for Testing:
•Centrate Pumps & Blend Tanks
•Thickening Centrifuges & Polymer Feed
Network Communication Block Diagram
Crisp Servers
Thickening & Dewatering Fiber Cabinet
Blower Building 1 Network Panel
Network Panel
Digester control Room Network Panel Solids 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 2 Truck Loading RIO Panel 3 Truck Loading RIO Panel 4 Truck Loading RIO Panel 5 Truck Loading RIO Panel 6
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
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 days
TOTAL 510 days
Delay to Commissioning Silos 1 & 3 132 days
Resolution of all Impacts & Implementation of
Completion Schedule
384 days
TOTAL 516 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
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 Update
Projection in
July 2017
Current
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?