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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?