Att 16 REV SBIWTP Capital Plan Report 2020 2024.pdf

2020-2024 Five Year Capital Plan Report

International Boundary and Water Commission International Wastewater Treatment Plant

Prepared by:

Veolia Water North America/CWE

2020-2024 Five Year Capital Plan Report

Prepared 1/30/2020

Table of Contents

1. Methodology Page 3

2. Capital Project and Cost Summary Page 4

3. Capital Project Details Page 8

Drawings, data, specifications, reports, and other documents, whether in electronic form or otherwise, prepared by Veolia Water North America West LLC (“Veolia”) are instruments of service for use solely by Veolia with respect to this project offering. Veolia shall at all times be deemed the author and owner of these respective instruments of service and shall retain all common law, statutory and other reserved rights, including, without limitation, all copyrights thereto. These instruments of service shall not be used by Client, either singularly or in conjunction with any third party, for any purpose whatsoever, including use by Client for such future additions or alterations to this project or for other projects, without the express prior written consent and agreement of Veolia, which consent and agreement may be withheld in Veolia’s sole and absolute discretion. Any unauthorized use of these instruments of service shall be at the Client’s sole risk and Veolia reserves all of its rights, both legal and equitable, for any unauthorized use of these instruments of service by any party, including, without limitation, the Client or anyone acting on its behalf. Veolia reserves the right to collect all instruments of service provided during meetings, presentations and other forms of communication if it so chooses.

SECTION 1 - METHODOLOGY

The following is a five year forecast of capital improvement project recommendations for the International Boundary and Water Commission International Wastewater Treatment Plant.

Recommendations for capital improvement projects are based on a comprehensive equipment/application assessment based on factors including:

Equipment Criticality Condition Assessment Projected Remaining Equipment Life Evaluation of External Factors

Tasks completed during the review conducted by Veolia included:

Criticality Review

A systematic relative criticality review was completed for the IBWC International Wastewater Treatment Plant. A criticality ranking process allows identification and prioritization of assets based on rankings from a standardized scale for consequence and likelihood of worst case failure scenarios. In a workshop with the plant staff and the Asset Management group, key criteria for each system were evaluated: Safety, Capacity, Environmental, Operating Cost, Stakeholder Impact, and Collateral Impact. The criticality ranking criteria is utilized during the capital planning process to prioritize repair/replacement decisions and timelines.

Condition Assessment

A condition assessment was completed for all major plant assets. The condition assessment is intended to be a “snap shot” of the condition of an asset and give it a ranking number based on deficiency scoring where 1 is new and 5 is failed. Lower numerical values represent best condition, based on deficiency scoring. In other words, evidence of defects, wear, or aging is necessary to give a higher value score. If an asset is in an advanced state of wear or aging, an end-of-life can be predicted. The purpose of developing a ranking number is to prioritize where maintenance and capital should be focused to increase reliability of system functions.

Each asset was ranked in multiple areas such as performance, appearance, vibration, reliability, safety, etc.

The concept is further expanded by breaking the life expectation down into three general stress related groupings to identify the expected life of the asset – light (non-corrosive), medium, and heavy (corrosive) duty for improved accuracy.

After the stress type is identified and an expected life span assigned, the years in service is calculated as the difference between the current date and the installation date for the asset.

Finally, the remaining expected life is calculated as the difference between the years in service and the expected life span.

Projected Remaining Equipment Life

The Projected Remaining Equipment Life is the development of the expected life cycle for each asset and determination of the remaining useful life. The Expected Life Tool is built on the concept that by grouping assets with similar failure modes it is possible to determine and apply statistical life expectancy for the group of assets. The life cycle data is built on studies conducted on life expectancy by different groups of asset types by the Veolia Environment Paris Technical Group. These asset types were further expanded on by published information and failure mode analysis of asset data from Veolia Water.

Evaluation of External Factors

Capital project work, while most often identified by applying the methodology described above, can also be driven by external factors such as equipment obsolescence, design deficiencies, improvements to save cost, etc. Such projects are developed on a case-by-case basis as needs are identified. They have been added to the Capital Plan as appropriate.

Capital Planning

The remaining expected life, in combination with condition ranking and plant priority, are used to establish capital improvement project recommendations for the next five years. Operational history is accounted for in the recommendations with a focus on projects that will improve operational efficiency and reliability. This projection has been limited to a five year ‘window’ to maximize accuracy. Estimated cost to complete each task was established using data from Veolia’s corporate database as well as locally established repair cost projections. Note that all capital improvement costs are based on present day (i.e. 2020-2021) dollars. Section 2 provides a summary of the projects and costs in this Capital Plan Report. Figure 1 graphically presents the annual cost burden for the required capital improvements. Section 3 offers a more detailed description on select projects of the work to be performed.

SECTION 2 – CAPITAL PROJECT AND COST SUMMARY

The table below is a cost summary of the recommended capital improvement projects. Note the project costs are estimates and each project will require a more detailed cost analysis prior to initiation of the projects. All costs are present-day dollar estimates.

Projects will be highlighted based on their funding origin as follows:

Type of Project Identifying Color

Veolia Funded Project BLUE

In Progress/Completed IBWC Funded Project RED

Proposed IBWC Funded Capital Project YELLOW

Projects In Progress/Completed in 2019

Project Cost Status

Replacement of Influent Pump 1 $280,000 Completed Replacement of Influent Pump 3 $280,000 Completed Polymer Feed Water System Maintenance $8,555 Completed Headworks PLC Redundancy, Equipment, Prog. $25,000 Completed Refurbishment of TWAS Pump 1 & 2 $12,000 Completed Solids Processing Lower Level Lighting Upgrade $12,600 Completed Influent Pump 6 Rebuild $88,000 Completed Influent Pump Motor Rebuild $6,400 Completed SCADA System Routine Maintenance $10,000 Completed Backflow Preventer Servicing $2,000 Completed IMLR Repairs $34,100 Completed AST Mixer Repairs $16,000 Completed Belt Filter Press Repairs/Belts $17,000 Completed Belt Filter Press Washwater Pump Repairs $7,740 Completed Truck Loading Conveyor Repairs $13,000 Completed Odor Control Fan Replacement / Repairs $31,000 Completed Truck Loading Scales Repair $29,000 Completed Pug Mill Repairs $6,000 Completed Grit Line Repairs $37,000 Completed Solids Processing Door Replacement $12,000 Completed Bar Screen Repairs $28,900 Completed Polymer Pump Repairs $5,000 Completed Belt Filter Press VFD Repairs $9,280 Completed Replaced Primary Channel Air Blower $8,000 Completed JB-1 Valve Inspection//Repair/Replace $6,000 Completed Phase 2 Arc Flash Study $49,000 Completed Refurbishment of Primary Skimmings Pump Electrical $5,000 Completed Air Compressor Service (7 air compressors) $9,765 Completed Flow Meter Servicing $2,000 Completed

Veolia Project Total $1,050,340

5-Year Capital Plan for 2020-2024

Year Project Cost

2020 JB-1 72" Valve Inspection/Repair/Replacement $1,700,000

2020 Replace Inf Meter Isolation Valves, Leaky Spool and Inspect Line $800,000

2020 Install Concrete Basin for Vactor Truck Dumping $100,000

2020 Polymer Feed Water System Maintenance $8,500

2020 Routine Equipment Maintenance and Repair $230,000

2020 Refurbishment Influent Pump 5 $80,000

2020 Odor Control Systems Refurbishment $60,000

2020 Replacement of Primary Skimmings' Troughs (2) $60,000

2020 Replace Primary Settling Tank Inlet Valves and Stems $50,000

2020 Facility Corrosion Control (Reoccurring) $50,000

2020 Replace Facility Gate Operators (1,2&5) $40,000

2020 Replacement Headworks Channel Covers $40,000

2020 Asphalt Repairs $30,000

2020 Replacement of Grit Air Blower #2 $30,000

2020 Overhaul Three Grit Classifiers / Separators $30,000

2020 Repair Aeration Basin Washdown Header $30,000

2020 Refurbishment of Primary Grit Disc Flo Pump #3 $30,000

2020 Process Air Blower Maintenance / Inspection $30,000

2020 Replacement of Truck Loading Bay Door $25,000

2020 Primary Tank Repair, parts $24,750

2020 Refurbish TWAS 1 and TWAS 2 pumps $24,000

2020 Replacement of HVAC Units $24,000

2020 Refurbishment of Primary Sludge Pumps (1 of 3) $20,000

2020 Refurbishment of Primary Sludge Pumps (1 of 3) $20,000

2020 Replace Goat Canyon Pump Station Main Utility Breaker $15,000

2020 Refurbishment of WAS Pump $15,000

2020 Belt Filter Press Belts $13,000

2020 Primary Sludge Pump VFD Repairs $10,640

2020 Improve Plant Signage $10,000

2020 Belt Filter Press VFD Repairs $10,000

2020 Goat Canyon Lift Station VFD Repairs $10,000

2020 Refurbish of Primary Skimmings' Pump $10,000

2020 SCADA System Routine Maintenance $10,000

2020 Replacement of PEB Meter Vault Sump Pump #1 & 2 $10,000

2020 Belt Filter Press Washwater Pump Repairs $7,000

2020 Replacement of DAF Air Compressors (2) $6,000

2020 Replacement of Effluent Meter Vault Sump Pump $5,000

2020 Operations Room Air Handling System Upgrade $3,200

2020 Flow Meter Servicing $2,000

2020 Capital Improvement Project Total $3,673,090

2020 Veolia Total $1,064,590

2020 Veolia Expenditure For The Year. $1,264,590

2021 Upgrade of Control Systems and I/O Cards $900,000

2021 Convert Manual Bar Screen #4 to an Automatic Bar Screen. $550,000

2021 Polymer Feed Water System Maintenance $8,500

2021 Routine Equipment Maintenance and Repair $245,000

2021 Refurbishment of Anaerobic Zone Mixers (13 out of 42 Units) $105,000

2021 Replace Aeration Basin Fine Bubble Diffuser Heads $80,000

2021 Asphalt Repairs and Coating $75,000

2021 Electrical Distribution Equipment Inspection $75,000

2021 Outfall Line Inspection $75,000

2021 Refurbishment of USST Sludge Mixing Pump 1 of 3 $70,000

2021 Odor Control Systems Chemical Tank Refurbish/Replace $60,000

2021 Replacement of Primary Skimmings' Troughs (2) $60,000

2021 Replacement Effluent Flow Meter (60" Magnetic) $60,000

2021 Facility Corrosion Control( Reoccurring) $50,000

2021 Replacement Canyon Collection Force Main Flow Meter (30" Magnetic) $30,000

2021 Process Air Blower Maintenance / Inspection $30,000

2021 Media Replacement for Purafil Filter Units $30,000

2021 Replacement of PST PolyBlend Polymer Activation/Feed System $30,000

2021 Replacement of Truck Loading Bay Door $25,000

2021 Site/Building Lighting $25,000

2021 Replacement of HVAC Units $24,000

2021 Replacement of PST Polymer Addition Pumps 1& 2 $20,000

2021 Replacement Canyon Collection Force Main Flow Meter (16" Magnetic) $15,000

2021 Replacement of PST Polymer Addition Pump 3 & 4 $15,000

2021 Refurbishment of TWAS Pumps $14,000

2021 Belt Filter Press Belts $13,000

2021 SCADA System Routine Maintenance $10,000

2021 Refurbishment of Dissolved Air Flotation Pressurization Pump 1 $7,500

2021 Belt Filter Press Washwater Pump Repairs $7,000

2021 Inspection of Hollister Street Pump Station Surge Tanks 1 & 2 $6,500

2021 Capital Improvement Project Total $2,715,500

2021 Veolia Total $1,257,000

2021 Veolia Expenditure For The Year. $1,457,000

2022 Replace corroded conduits and wiring in Solids Processing Building $425,000

2022 Polymer Feed Water System Maintenance $8,500

2022 Routine Equipment Maintenance and Repair $260,000

2022 Refurbishment of Primary Grit Disc Flo Pumps (3) $90,000

2022 Pump 1, Submersible, GCPS 04103-P1 $90,000

2022 Replace chemical storage tanks (1) $80,000

2022 Replacement of Sodium Hypochlorite Storage Tank $80,000

2022 Secondary Settling Tanks Rebuild (1 of Original 10 tanks) $80,000

2022 Outfall Line Inspection $75,000

2022 USST #1 Cleaning $70,000

2022 Refurbishment of USST Sludge Mixing Pump 1 of 3 $70,000

2022 Odor Control Systems Refurbishment $60,000

2022 Facility Corrosion Control( Reoccurring) $50,000

2022 Replacement of Truck Loading Bay Door $25,000 2022 Site/Building Lighting $25,000 2022 Replacement of HVAC Units $24,000

2022 Refurbishment of Primary Sludge Pumps (1 of 3) $20,000 2022 Refurbish Silo 1 Lime Stabilization System $15,000 2022 Refurbish Silo 2 Lime Stabilization System $15,000 2022 Belt Filter Press Belts $13,000 2022 SCADA System Routine Maintenance $10,000 2022 Refurbishment of Secondary Skimming Pump (1 out of 2 Units) $10,000 2022 Replace Junction Box #1 72-inch Motorized Valve Actuator $10,000 2022 Refurbishment of Dissolved Air Flotation Pressurization Pump 2 $7,500 2022 Belt Filter Press Washwater Pump Repairs $7,000 2022 Grinder 1, Primary Sludge 00475-PSG1 $6,000 2022 Capital Improvement Project Total $1,626,000 2022 Veolia Total $1,186,500

2022 Veolia Expenditure For The Year. $1,286,500

2023 Replacement Sludge Lime Mixers (1 0f 2 Pug mills) $250,000 2023 Replacement of Truck Loading Conveyors $200,000 2023 Polymer Feed Water System Maintenance $8,500 2023 Routine Equipment Maintenance and Repair $275,000 2023 Refurbishment of Primary Grit Disc Flo Pumps (3) $90,000 2023 Repair 1 PST and internals, not including valves and actuators $85,000 2023 Secondary Settling Tanks Rebuild (1 of Original 10 tanks) $80,000 2023 Outfall Line Inspection $75,000 2023 Refurbishment of USST Sludge Mixing Pump 1 of 3 $70,000 2023 USST #2 Cleaning $70,000

2023 Odor Control Systems Refurbishment $60,000 2023 Odor Control Systems Chemical Tank Refurbish/Replace $60,000 2023 Repair of Personnel/Maintenance Building Roof $57,300 2023 Facility Corrosion Control( Reoccurring) $50,000 2023 Asphalt Repairs $50,000 2023 Refurbishment of Intermediate Mixed Liquor Pumps 2 of 7 $40,000 2023 Refurbishment of Primary Grit Disc Flo Pump #2 $30,000

2023 Process Air Blower Maintenance / Inspection $30,000 2023 Replacement of Truck Loading Bay Door $25,000 2023 Site/Building Lighting $25,000 2023 PEB 48" Mag Flow Meter $25,000 2023 Replacement of HVAC Units $24,000 2023 Secondary Channel Aeration Blower Refurbishment $15,000 2023 Belt Filter Press Belts $13,000 2023 SCADA System Routine Maintenance $10,000 2023 Belt Filter Press Washwater Pump Repairs $7,000 2023 Capital Improvement Project Total $1,724,800 2023 Veolia Total $1,266,300 2023 Veolia Expenditure For The Year. $1,466,300

2024 Relining of PST Effluent Channel $500,000 2024 Repair Belt Filter Press 1 of 4 $85,000 2024 Polymer Feed Water System Maintenance $8,500 2024 Routine Equipment Maintenance and Repair $325,000

2024 Secondary Settling Tanks Rebuild (2 of Original 10 tanks) $160,000 2024 Refurbishment of Anaerobic Zone Mixers (13 out of 42 Units) $105,000

2024 Replace chemical storage tanks (1 of 2) $80,000

2024 Replace chemical storage tanks (2 of 2) $80,000 2024 Repair Mechanical Barscreen (1 of 3) $75,000 2024 Outfall Line Inspection $75,000 2024 Odor Control Systems Refurbishment $60,000 2024 Facility Corrosion Control( Reoccurring) $50,000 2024 Repair Aeration Basin Washdown Header $30,000 2024 Replacement of Truck Loading Bay Door $25,000 2024 Site/Building Lighting $25,000 2024 Primary Settling Tank Miscellaneous Parts (shoes, wear strips, gears, etc.) $24,750 2024 Replacement of HVAC Units $24,000 2024 Non-Potable Water Pump VFD Repairs $21,280 2024 Replace Goat Canyon Pump Station Main Utility Breaker $15,000 2024 Belt Filter Press Belts $13,000 2024 Primary Sludge Pump VFD Repairs $10,640 2024 SCADA System Routine Maintenance $10,000 2024 Belt Filter Press Washwater Pump Repairs $7,000 2024 Replacement of DAF Air Compressors (2) $6,000 2024 Capital Improvement Project Total $1,815,170 2024 Veolia Total $1,221,670 2024 Veolia Expenditure For The Year. $1,321,670

Figure 1. Projected Capital Expenditures

Capital Improvement Projects:

Figure 2. Projected Capital Expenditures

Veolia Projects:

SECTION 3 - CAPITAL IMPROVEMENT PROJECTS – Description of Selected Projects

Many of the projects listed in the above capital plan are self-explanatory. Some projects are more complex and require further discussion. This is provided below.

2020 to 2024 – Polymer Feed Water System Maintenance – The polymer feed water system funded in 2016, and installed in 2016-2017, requires annual maintenance. As this system was installed post the 2015 contract award, these maintenance costs were not included in Veolia’s maintenance pricing. Annual funding is required.

Non-Recurring Projects

2020 – End of Design Life - Gate Operators for Gates 1, 2, and 5 – After many years of service and with increased gate traffic over the past several years, the motorized operators for Gates 1, 2, and 5 have reached the end of their design life. Complete replacement is recommended.

2020 – Dirt Disposal Concrete Pad and Drain – Since the modification of the Smugglers and Goat Canyon collectors, a significant increase in incoming dirt and debris has been observed during rainfall events. This material must be promptly removed in compliance with contract terms and to ensure that flow from subsequent discharge events is not impeded. However, the dirt and debris removed following rain events is too wet to be accepted at the landfill disposal site and must be allowed to dry. Insufficient hard surface space is currently available. It is proposed that a concrete pad with a drain be constructed at a location to be determined.

2020 – Defective Primary Settling Tank Inlet Valves and Stems – The original construction of the Primary Settling Tank Inlet Valves involved a design which utilized a non-rising stem which provides staff with no indication of valve position. Valve stems were constructed with full length threading which weakens the stems, causing twisting and bending when the valves are operated.

Valve stems and operators are therefore considered defective and require replacement.

2020 – Improve Plant Signage – With the completion of IBWC’s new on-site administration building and ongoing security improvements, relocation of the facility’s main entrance will likely be to Gate 5. Increased traffic is being experienced. In order to streamline traffic flow, an improvement in plant signage is recommended which will help direct those unfamiliar with the plant site layout to the correct location.

2021 - Control System Upgrade and Integration Project – the current control system utilizes Human Machine Interface (HMI’s) units and Programmable Logic Controllers (PLC’s) to allow control and system communication for process control and data acquisition. The PLC’s are currently functional however have exceeded their life expectancy and are no longer supported by the manufacturer. Should the PLC’s malfunction there is no recourse to repair them.

Replacement is necessary. Veolia has replaced several of the PLC’s, but without a pronounced and involved remediation the PLC’s will not communicate as a system, but rather function as standalone systems. As the systems run in standalone mode the communications and subsequent control speed is substantially reduced. A System Integrator is needed to replace, install and integrate the PLC’s into the Control System.

2021 - Replacement of Aeration Basin Fine Bubble Diffuser Heads – Veolia’s experience has been that the rubber aeration fine bubble diffuser heads will fail after several years of normal use.

When a head fails, it dramatically upsets wastewater aeration in that basin as well as likely impacting aeration in other basins. Veolia recommends that IBWC plan to proactively replace the rubber diffuser heads.

2021, onwards – Replacement of Magnetic Flow Meters – Veolia’s operating experience has indicated that the flow tube portion of magnetic flow meters will fail due to wear over time.

Replacement of these flow meters has been recommended as the meter tubes will have reached the end of their design life.

2022 – Replacement of Sodium Hypochlorite Storage Tanks (2) – The combination of the effects of weather, age, and the acidic nature of sodium hypochlorite have combined to require that these fiberglass tanks be replaced.

2023 - Replacement of Sludge Lime Mixer (Pug Mills) – It is well known that the plant’s two pug mills have required many maintenance repair hours and dollars. The introduction of additional solids generated by the secondary system has required increased operating hours as well as further mechanical stress due to the ‘gummier’ nature of these wastes. Veolia projects that the housing and basic structure of the existing pug mills will reach a point where repair is no longer viable. Replacement will be required.

2022 – Replacement of Influent Wet Well Isolation Gates – The isolation gates and tracks are corroded and in need of replacement.

2023 – Replacement of 3 Mechanical Bar Screens – In 2013 the Mechanical Bar Screens were refurbished and will be in need of further attention by 2023. Many sections of the track runners have become fatigued allowing the rack and gears to become stuck. Refurbishment will not address the metal fatigue requiring replacement.

2024 – Rebuild 4 Belt Filter Presses - In 2013 the Belt Filter Presses were rebuilt and will be in need of rebuild by 2023.

2020, 2021, and 2022 – Pumps numbered 1, 3 and 6 are being replaced in 2020. Heavy usage combined with the heavy sand and grit loading common in the IWTP influent results in higher than normal wear rates and more frequent major repairs. After 21 years of service, all pumps are reaching their useful service life. Although repairs have been regularly performed as needed, the accumulated wear on major pump components is anticipated to render these pumps non-repairable in the next few years. Veolia, therefore, recommends complete replacement of the pumps.

Capital Projects to Consider Due to High Condition Assessment Score

Although imminent failure of the following equipment is not indicated, the projects listed below should be considered as possible additions to this Capital Plan due to condition assessment scores that rank them as near failing (4 and above):

o Intermediate Mixed Liquor Recycle Pumping System Rank: 5.0 o Headworks Building, FANCNT Rank: 5.0 o USS Mixing Pumping System, WEMCOPUMP Rank: 5.0 o Sludge Truck Loading Area, FANCNT Rank: 5.0 o Sludge Dewatering Polymer Dosing System, MOYNOPUMP Rank: 5.0 o PST Skimming Troughs and the actuators Rank: 5.0