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Home My WebLink AboutItem 5 PPP 03-06-19 Ops Committee - P1-105 Budget Increase �• 1 . J o = Ec•' E a� u � °' � o o � J Q }' 1 '10 / , C6 V 3 � � L \ Lf) ro �� , '" AV • • • � • • • ! AM& OR M � r a \ � � o 4.9 AA. 1 • • • � • • • 1 .-�1 �.; ��,II �� ` � . � '•fir a I,� M � � 1 t Project Update — January 2019 Operations Committee 0% Desig Budget: $370 millio Estimated Budget: 425 million Construction Cost: $255 milli stimated Construction: $295 milli Project Definition Increases As Design Progresses Maturity of Project Definition Project Stage Sta rt Completion Level 0% Design Scope list, Documentation 0 dwgs a Q< � Q��rsY". A v a��a0o� P Project Definition Increases As Design Progresses Maturity of Project Definition Project Preliminary Stage Start Design Completion Level 0% 10-20% Design Scope list, Tech memo, Documentation 0 dwgs 197 dwgs • i � b a' �, rROJtCT NO_ P1-�Os - !! AT HEADrM Kfi HEfAN1 1t AtpN \ AT PLANT N( T a" VINAL PRELIMINARY OESIGN_ SUBMITZ A>_ VOLUME 11 OF 11 DRAWINGS �' � `%--{-._ __. _ SAMTAT l9/ 01STNK.T -_••-•• MA wcC Cppfpl\ 4rcar I I Project Definition Increases As Design Progresses Maturity of Project Definition Project Preliminary Design Stage Start Design (DS2) Completion Level 0% 10-20% 50-60% Design Scope list, Tech memo, 50% specs, Documentation 0 dwgs 197 dwgs 1,698 dwgs PROJECT NO. P1-105 Headworks Rehabilitation at Plant No.1 SPECIFICATIONS DIVISION 0- BIDDING REQUIREMENTS, CONTRACT FORMS, AND CONDITIONS OF THE ,'•`•'•'•• ` • ••• , ' '``'"` CONTRACT r r JIJLY�1i0�0 DIVISION 1- GENERAL REQUIREMENTS ' OE'310N SUBMITTAL NO.Q✓Q� Section No. Section Title 01110 Summary of Work ... - 01120 Work Sequence vo�.uME ttl 01140 Work Restrictions 01155 Measurement and Payment 01300 Contractor's Construction Schedule and Reports _.—-- 01332 Seismic Design Criteria 01353 Special Procedures for Locating and Verifying Concealed Existing Utilities I- S\ t rtxwrrv/b- 01450 Quality Assurance-Quality Control Program 01455E Special Tests and Inspections 01500 Temporary Facilities and ConVols 01600 Shipping.Storage.and Handling 01614 Wind Design Criteria 01701 Project Control Management System(PCMS) 01722 Field Engineering 01763 Equipment Service Manuals 01611 Commissioning Dashboard 01620 Training of OCSD Personnel 01900 Hazardous Materials Mitigation and Controls 01950 Mold Remediation and Contmis DIVISION 2- SITE CONSTRUCTION Section No. Section Title 02050 Demolition 02,10 Clearing Grubbing and Shipping .154 Eerih Anchors 02200A Earthwork 02200E Excavation Support and Protection 02200C Dewatering 02232 Preparation of Pavement Subgrade Project Definition Increases As Design Progresses Maturity of Project Definition Project Preliminary Design Design - Stage Start Design (DS2) (DS3) . Completion Level 0% 10-20% 50-60% 90-95% Design Scope list, Tech memo, 50% specs, 90% specs, life • - Documentation 0 dwgs 197 dwgs 1,698 dwgs 2,200 dwgs • : PROJECT NO. P1-105 Headworks Rehabilitation at Plant No.1 r �1• c�1-th SPECIFICATIONS r�1 �:I�iN F�IJpMI�fAL NO.'iC DIVISION O- BIDDING REQUIREMENTS, CONTRACT FORMS, AND CONDITIONS OF THE CONTRACT DIVISION 1- GENERAL REQUIREMENTS VOLUME Its mRAWltypg Section No. Section Title 01110 Summaryot Work �c 01120 Work Sequence 01140 Work Restrictions ` �rCa�/b✓wO' - 01155 Measurement and Payment 013DO Contractors Construction Schedule and Reports 01332 Seismic Design Criteria 01353 Special Procedures for Locating and Verifying Concealed Exii Utilities 01450 Quality Assurarlos-Quality Control Program 01455B Special Tests and Inspections 016DO Temporary Facilities and Controls 016DO Shipping,Storage,and Handling 01614 Wind Design Criteria 01701 Project Control Management System(PCMS) 01722 Field Engineering 01763 Equipment Service Manuals 01811 Commissioning Dashboard 01820 Training of OCSD Pereonnel 019DO Hazardous Materials Mitigation and Controls 01950 Mold Remediation and Controls DIVISION2- SITE CONSTRUCTION Section No. Section Title 02050 Demolition 02110 Clearing Grubbing and Stripping 02164 Earth Anchors 022DOA Earthwork 022DOB Excavation Support and Protection 02200C D—atering 02232 Preparation of Pavement Subgrade Project Definition Increases As Design Progresses Maturity of Project Definition Preliminary Design Design - Design (DS2) (DS3) . 10-20% 50-60% 90-95% l 1 ' . +30% , +15% 0% -15% -30%i Estimated Budget at 50% Design Maturity of Project Definition Preliminary Design Design - Design (DS2) (DS3) . 10-20% 50-60% 90-95% loss +30% $328M +15% $295M 0% $255M -30%— $166M Why Has the Project Cost Increased ? Further design development identified additional elements, cost, and complexity • Constructability challenges • Site space constraints • Construction sequencing for operating facility • Risk reduction measures • Opportunity to include future/other projects more cost- efficiently Construction Increases L w- 6M Previous Estimate $255M Increased Rehab Requirements $14M Risk reduction measures $10M Future/other projects $16M Total $295M Increased Rehab Requirements ( $ 14 million ) • New below-grade entrance into M&D structure • Motor actuators for 101 gates • Grit head box structure • Demolition of hydrogen peroxide facility • Demolition of Power Building 1 • Demolition of PCI and EIM trailers • Demolition of buried original headworks structure • Replacement of Metering and Diversion (M&D) building • 12 kV power feed to SALS • New 4160V electrical system for MSPs • Rehabilitation/repairs for MSP flap gates • Relocation of grit basin foul air ducting • Primary influent splitter box modifications • Temporary grit low pressure air piping • Temporary odor scrubber chemical facilities • Temporary influent sampling system • Tunnel S extension and new Tunnel 7A • Stainless steel piping in M&D structure M & D Building Replacement • M&D Building is above meter structure that4 requires meter and ,.000' - - piping replacement : --- UL • To improve both . constructabilitY and future meter ,f, maintenance, deck openings are required • M&D Building must be � T demolished and replaced elsewhere All s Ms- L r� I I _ I'. Illl'1 IIUI/ Risk Reduction Measures ($ 10 million ) • Dual diesel tanks for standby generators • Influent pump station concrete coring • Early MSP intake replacement • Arc resistant electrical facilities • Replacement of stop plates • Temporary trunk line odor control chemical facilities • Permanent load bank for standby generators • Gate assessment Arc Resistant Electrical Facilities • Arc flash presents a life safety hazard at our electrical facilities rr ; • Recent advancements in electrical equipment and facility design can greatly reduce risk • OCSD has adopted arc resistant design - requirements to be implemented on P1 105 `LLI n � Ir TL r � Expanded Project Scope ($ 16 million ) • Additional standby power capacity • Server room in new power building • 12 kV power feed to future Headquarters Complex • Expanded air compressor facility with instrument-quality air • Expanded pavement replacement • Instrument air pipeline replacement • Potable water piping replacement in yard • Ferric chloride facility for CEPT and digesters • Replacement of trunk line odor control chemical facility • Blower Building 1 demolition modifications • Power Building 2 demolition modifications • Power Building 3A demolition • Rehabilitation of Talbert Trunk sewer • Temporary digester ferric chloride pumping • Collection system diversions for M&D Box repair Additional Standby Power Capacity • Two additional generators in P1-105 building replace three end-of-life generators for other processes = � . • Provides centralization of generators, c commonality of equipment • Recommend proceeding with additional generators for best f r cost-eff i c i e n cy = �� Alternatives Maturity of Project Definition Preliminary Design Design - Design (DS2) (DS3) . 10-20% 50-60% 90-95% l 1 ' . +30% $328M +15% $295M i►♦$292M C 0% $270M B $255M $255M A -30%— $166M Changes Common to All Alternatives • Value engineering ideas • Appropriate deferrals to other projects • Two additional standby generators for other areas Net Impact: 3 million construction cost savings Defer Odor Control Existing facilities at end of life , I' i Project was to replace - • facilities * Savings does not include rehabilitation cost / * $23M construction cost savings _- Defer New Grit Handling • Grit removal/handling • • • • of headworks • • Replace old technology to improve grit capture y,. Improve reducing odors Provide drier ,�� ■ �r�_. GRIT PIPE(TYP) reduces hauling costs GRIT WASHER(TYP) $ 14 million ®�1% EQUIPMENT PLATFORM \r construction • Alternative A —$ 255M Construction Cost Maturity of Project Definition Preliminary Design Design Design (DS2) (DS3) . 10-20% 50-60% 90-95% • Include value engineering ideas +30% No new grit handling • No odor control work $328M +15% $295M 0%-- \ z \ $255M +$255M A -15% Avoids budget increase • More grit into plant • Potential odor complaints and permit violations -30%— $166M due to aging equipment 0 Odor control and grit handling deferred to future Alternative B - $ 270M Construction Cost Maturity of Project Definition Preliminary Design Design Design (DS2) (DS3) . 10-20% 50-60% 90-95% l 1 ' . • Include value engineering ideas +30% Include odor control improvements • No new grit handling $328M +15% $295M 0% $270M B $255M • Requires $15M more project budget • More grit into plant $166M 0Reliable odor control facilities -30%— 19 Grit handling deferred to future Alternative C —$ 292 M Construction Cost Maturity of Project Definition Preliminary Design Design Design (DS2) (DS3) . 10-20% 50-60% 90-95% l 1 ' . • Include value engineering ideas +30% Include odor control improvements • Include new grit handling $328M +15% $295M �►♦ $292M C 0%-- \ $255M • Requires $36M more project budget • Less grit into plant -30%— $166M Full odor control improvements Summary of Alternatives ��AlConstructionAlternative Project mid Budget A — No odor control, no $255 million $370 million new grit handling B — Odor control without $270 million $385 million new grit handling C — Odor control and new $292 million $406 million grit handling Staff recommends Alternative C: • Odor control facilities are at their end of life • Odor control represents permit compliance and a commitment to a level of service • Grit removal is a core function of a headworks, and improved grit removal prevents damage to downstream processes Increased Design Costs • Design costs increase along with construction costs • Detailed "bottoms-up" review of costs to complete • Extensive negotiations with Carollo to reach agreement • Staff believes negotiated upper limit represents fair and reasonable budget to complete the design . • Design costs low compared to other large rehabilitation projects • Rehab typically 11 to 25% of construction costs • 9% with proposed increase Recommended Actions • Approve a budget increase of $36,000,000 for Headworks Rehabilitation and Expansion at Plant No. 1, Project No. P1-105, for a total budget amount of $406,000,000 • Approve a contingency increase of $5,083,398 (29%) to the Professional Design Services Agreement with Carollo Engineers for the Headworks Rehabilitation and Expansion at Plant No. 1, Project No. P1-105, for a total contingency amount of $8,939,398 (51%) .