LRWRP_Design_Report_TOC.pdf
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- Solicitation number
- 2025-RFP-015DW
- Issued by
- Santa Barbara County, Long Beach City, California
About this file
This is a Design Report Table of Contents and project documentation for the City of Lompoc's Regional Wastewater Reclamation Plant upgrade project, serving approximately 9,000 sewer connections with a current Average Dry Weather Flow capacity of 5.0 MGD in Santa Barbara County, California. The comprehensive project encompasses headworks improvements including screenings removal, influent pumping system replacement, flow metering and sampling, grit removal systems, and vactor truck unloading stations; secondary treatment facility upgrades involving oxidation ditches and secondary clarifiers; metals removal facilities with tertiary flocculators and clarifiers; effluent filtration systems; ultraviolet disinfection equipment; and solids handling facilities including thickening, anaerobic digestion, and biosolids processing. Additional work includes electrical and instrumentation system upgrades, miscellaneous infrastructure improvements, storm water drainage, paving, site grading, and evaluation of a microturbine cogeneration system utilizing digester gas. The project is structured in multiple treatment modules (TM 1-8) with a phased implementation approach. A mandatory pre-bid job walk is scheduled for May 14, 2025, with proposals due by June 30, 2025, at 3:00 pm, valid for 90 calendar days after bid opening.
The preliminary estimate of probable construction costs ranges significantly depending on project scope, with referenced estimates from previous design phases spanning approximately $300,000 to over $41 million for comprehensive facility upgrades. Compensation for the selected engineering consultant will be based on approved actual time and materials, not to exceed an agreed-upon "Not-to-Exceed Fee," with progress-based payments contingent on task completion. The selected firm must provide comprehensive design and engineering services including preliminary and final design documents, construction documents, and operation and maintenance manuals. Insurance requirements mandate $1,000,000 in Errors and Omissions Professional Insurance plus additional coverage for general liability, automobile liability, and worker's compensation. The project builds upon previous master planning efforts, including a 2002 master plan by Kennedy/Jenks Consultants and this 2005 design report by Brown and Caldwell, which identified necessary infrastructure upgrades at the facility. The contract does not explicitly specify set-aside designations for disadvantaged enterprises.
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CONTENTS
TABLES ............................................................................................................................................................ vi ......................................................................................................................................................... F I G IIRI 1S vii
CHAPTER 1 RECOMMENDED PROJECT ........................................................................................ 1-1
................................................................................................................................... 1 . 1 Introduction 1-1
1.2 I-Ieadworks Improvements ..................................................................................................... 1-3 ......................................................................................................... 1.2.1 Screenings Removal 1-3
1.2.2 Influent Pumping ............................................................................................................. 1-3
1.2.3 Influent Flow Metering and Sampling .......................................................................... 1-5
................................................................................... 1.2.4 Vactor Tnlck Unloadmg Station 1-6 ...................................................................................................... 1.2.5 Grit Removal System 1-6
. . ........................................................................................................ 1 2 . PWWF Equahzation 1-8 ................................................................................................................... 1.2.7 Recycle Flows 1-9
................................................................................................... 1.3 Secondary Treatment Faclltties 1-9
1.3.1 Existing Facdities ........................................................................................................ 1-9
........................................................................................................... 1.3.2 Oxidation Ditches 1-9 ...................................................................................................... 1.3.3 Secondaq Clarifiers 1-13
1.3.4 RAS/WMLPumpingSystem ...................................................................................... 1-14 . . . ........................................................................................................... 1.4 Metals Removal Faclllues 1-14
1.4.1 Secondary Effluent Flow Equahzatlon ....................................................................... 1-15
............................................................................ 1.4.2 Chelnical Storage and Feed System 1-1 6
1.4.3 Tertiary Flocculators/Clarifiers ................................................................................... 1-19
1.5 Effluent Filters ....................................................................................................................... 1-19 .......................................................................................................... 1.5.1 Existing Facdities 1-19
...................................................................................................................... 1.4.2 FlowRates 1-19
1.5.3 Filtration Objectives ...................................................................................................... 1-19
................................................................................ 1 S.4 Recoinmended Filter Fadt ies 1 - 2 0
............................................................................................................... 1.5.5 Design Cnterm 1-21 ............................................................................................. 1 S.6 Materials of Construction 1-21
................................................................. 1.5.7 Effluent Filter Arrangement and Support 1-21 . . .............................................................................................................. 1.6 Ultraviolet Dlslnfection 1-23
......................................................................................................... . 1.6 1 Existing Faclltties 1-23
................................................................................... 1.6.2 Master Plan Recommendations 1-23 ...................................................................................................................... 1.6.3 Flow Rates 1-23
................................................................................................ 1.6.4 Disinfection Objectives 1-23 .............................................................. 1.6.5 Recolnmended UV Disinfection Facdities 1 - 2 4
. ............................................................................................................... 1 6.6 Design Criteria 1-24 .............................................................................. 1.6.7 Structure and Support Equipment 1-25
.......................................................................... 1.6.8 U\T Disinfection Equipment 1, ayout 1-26
1.7 Solids Handling Facilities .................................................................................................... 1-26
........................................................................................................... 1.7.1 Existing F'achties 1-26
.......................................................................................................... 1.7.2 Solids Prolectlons 1-28
CONTENTS (continued) 11
? 3 . 1.7.3 Existing Gravity 1 luckeners ........................................................................................ 1-29
1.7.4 Waste Mixed Liquor Thickening .............................................................................. 1-30
1.7.5 Anaerobic Dlges tion ..................................................................................................... 1-31
1.7.6 Sludge Lagoons .............................................................................................................. 1-31
1.7.7 Biosolids Drying Beds ................................................................................................... 1-32
1.7.8 Biosolids Storage ............................................................................................................ 1-32
1.8 Electrical and Instrumentation ............................................................................................. 1-32
1.8.1 Electrical Power Distribution .............................................................................. 1 - 3 2
1.8.2 Instrumentation and Control ................................................................................... 1 - 3 3
............................................................................................... 1.9 Miscellaneous Improvements 1 - 3 5
1 . 9.1 improvements to the Existing Structures and Equipment ..................................... 1-35
1.9.2 Storm Water Drainage ................................................................................................. 1-39
1.9.3 Paving and Contractor Staging Area .......................................................................... 1-40
1.9.4 Site Gradmg .................................................................................................................... 1-40
............................................................................................................. 1.1 0 Detailed Design Criteria 1-40
. 1 11 Flow Diagram ............... : ............................................................................................................. 1-46 1 . 12 Plant Layout ......................................................................................................................... 1 - 4 6
1.13 P r e b a r y I-Iydraulic Profile .......................................................................................... 1 - 4 6
CI-IAPTER 2 PROJECT COST AND SCHEDULE ............................................................................. 2-1
............................................................. 2.1 Preliminary Esulnate of Probable Construction Cost 2-1 ........................................................................................................ 2.2 Recommended Project Cost 2-2
.......................................................................................................................... 2.3 Cost Comparison 2-2
2.4 Project Schedule ............................................................................................................................ 2-3
CHAPTER 3 HEADWORKS IMPROVhfENTS (TM 1) .................................................................... 3-1
Introduction ............................................................................................................................... 3 - 1 Objectives ................................................................................................................................. 3-1
Replacement of Influent Pumps ............................................................................................ 3-2
3.3.1 Existing Condtions ......................................................................................................... 3-2
3.3.2 Proposed Conditions ...................................................................................................... 3-3
3.3.3 Alternative A - Eslst~ng Pumping Station ................................................................... 3-4
......................................................................... 3.3.4 Alternative B - New Pumping Station 3-5
3.3.5 Discussion and Recommendation ................................................................................. 3-6 Influent Flow Measurement and Recycle St-reams .................................................................. 3-6
3.4.1 Background ....................................................................................................................... 3-6
3.4.2 Discussion and Recommendations - Recycle Flows ............................................... 3-6
3.4.3 Discussion and Recommendations - Influent Flow Mcasurement ....................... 3-7 Vactor Truck Unloadng Station ................................................................................................. 3-7
Grit Removal and Processing ...................................................................................................... 3-7
3.6 . 1 Vortex Grit Removal .................................................................................................... 3-8
3.6.2 Aerated Tank Grit Removal ........................................................................................... 3-8
3.6.3 Grit Separation and Dewatering ....................................................................... 3 - 8
3.6.4 Grit Storage and Disposal .............................................................................................. 3-9
3.6.5 Discussion and Recommendations ............................................................................. 3-10
February 2005
CONTENTS (continued) u1
3.7 Flow Diversion to Einergency Moldmg Basin ........................................................................ 3-11
3.8 Comparative Costs of Conceptual Alternatives ...................................................................... 3-12
3.9 Prehntnaq Construction Cost .................................................................................................. 3-14
CI-IXITER 4 SECONDrIRY 'rREXTh4ENT (Thf 2) ........................................................................... 4-1
................................................................................................................................. 4.1 Introduction 4 - 1
4.2 Objectives ....................................................................................................................................... 4-2 ........................................................................................................................... 4.3 Existing Facilities 4-2
4.3.1 Influent Flows and Loads ............................................................................................... 4-3
4.3.2 Other Parameters ............................................................................................................. 4-8
4.3.3 Wastewater Character~zauon ..................................................................................... 4-9
4.4 Process Interactions ...................................................................................................................... 4-9
4.4.1 Upstream Processes ......................................................................................................... 4-9
4.4.2 Downstream Processes ................................................................................................... 4-9
........................................................................................................ 4.5 Process Recommendations 4-10 .................................................................................................. 4.5.1 Stage 1 Improvements 4 1 0 .................................................................................................. 4.5.2 Stage 2 Improuements 4-14
............................................................................................................................ 4.6 Design Criteria 4-16 7 . 4.7 P r e h n a q Cost Istunate ......................................................................................................... 4-17
CHAPTER 5 METALS REMOVrZL ('IN 3) .......................................................................................... 5-1
................................................................................................................................... 5.1 Introduction 5-1
5.2 Recommended Inves~gatlons ................................................................................................ 5-1
5.3 Objectives ................................................................................................................................ 5-2
5.4 Existing Facilities .................................................................................................................... 5-3
5.4.1 Influent and Effluent Metals Concentrations ............................................................. 5-3
5.5 Process Interactions ................................................................................................................ 5-4
5.5.1 Upstream Processes ....................................................................................................... 5-4
5.5.2 Downstream Processes ............................................................................................ 5-4
5.6 Process Recommendations ........................................................................................................ 5-4
5.7 Design Criteria .......................................................................................................................... 5-7
5.8 Prehninaq Cost Estimate .......................................................................................................... 5-9
CHAPTER 6 EFFLUENT FILTRATIONS ('I'M 4) ............................................................................. 6-1
6.1 Introduction ................................................................................................................................... 6-1
6.2 Objectives ................................................................................................................................. 6-1
6.3 Flow and Water Quality Projections .......................................................................................... 6-2
........................................................................................................................ 6.3.1 Flow Rates 6-2
6.3.2 Permit Requi~emcnts .................................................................................................... 6-2
........................................................................................................ 6.3.3 Filtration Objectives 6-2
6.4 Effluent Filtration .................................................................................................................. 6-3 . .......................................................................... 6.4.1 Evaluation of Plltration Technologies 6-3
6.5 Recommended Effluent Filter Design Criteria ......................................................................... 6-6
.................................................................................................. 6.6 Ilescr~ptlon of bllter Operation 6-7
CONTENTS (continued) iv
Normal Filter Operation ................................................................................................ 6-7 ..................................................................................................................... Backwashing 6-8
S e t h g ............................................................................................................................... 6-8 .......................................................................................................................... Service 6 - 8
6.7 Materials of Construction ....................................................................................................... 6-9 ................................................................................ 6.8 Effluent Filter Arrangement and Support 6 -9
........................................................................................................................ 6.9 Preliminary Costs 6-12 ........................................................................................ 6.1 0 Conclusions and Recommendatiolls 6-12
CHAPTER 7 DISINFECTION (TM 5) ................................................................................................... 7-1
................................................................................................................................... Introduction 7-1 Objectives ................................................................................................................................. 7-1
Flow and Water Quality Projectlons .......................................................................................... 7-2
7.3.1 Flow rates .......................................................................................................................... 7-2 ...................................................................................................... 7.3.2 Permit Requirelnents 7-2
.................................................................................................. 7.3.3 Disinfection Objectives 7-2
.................................................................................................. 7.3.4 Total Residual Chlorine 7-2
Effluent Dlslnfection ................................................................................................................... 7-3
7.4.1 Evaluation of UV Disinfection Technologies ............................................................. 7-3 .................................................................................................... 7.4.2 Design Considerations 7-6
7.4.3 Evaluation of UV System Options ............................................................................... 7-8
7.4.4 Summal-): of UV Equipment Information ................................................................. 7-11
............................................................................................................... 7.4.5 Design Criteria 7-11
................................................................................................. Structure and Support f a c h e s 7-15!
..................................................................................... UV Disinfection Equipment Layout 7 - 1 2
........................................................................................................................... Estitnated Costs 7-13
7.7.1 P r e h n a r y Construction Costs ................................................................................... 7-14
............................................................................................................. 7.7.2 Operating Costs 7-14 ........................................................................................ Conclusions and Kecomlnendations 7-15
CHAPTER 8 SOLIDS HANDLING FACILITIES (TM 6) ................................................................ 8-1
................................................................................................................................... 8.1 Introduction 8-1 ....................................................................................................................................... 8.2 Objectives 8-1
. . .............................................................................. 8.3 Existing Conditions and Solids Projections 8-3 ......................................................................................................... 8.3.1 Existing Conditions 8-2
8.3.2 Solids Projections ...................................................................................................... 8-3
8.4 Sludge Thickening .................................................................................................................... 8-4 . ............................ 8.4.1 Evaluation of Existing Gravity Thtckening vs DrZF Thickening 8-4
............................................................................................................................. 8.5 Solids Digestion 8-7 ........................................................................................................ 8.5.1 WAS Disintegration 8-8
8.5.2 Digestion Process Issues ............................................................................................... 8-8 .............................................................................................................................. 8.6 Sludge Lagoons 8-9
.................................................................................................. 8.6.1 Class A Biosolids Issues 8-9 ................................................................................................. 8.6.2 Lagoon Improvements 8-10
CONTENTS (continucd) v
8.7 Sludge Air Drying Bed and Dricd Product Storage .............................................................. 8-12
8.7.1 Drying Bed and Product Storage Improremcnts ..................................................... 8-12 ..................................................................................................................... 8.8 Recommendations 8 - 1 3
8.8.1 Staget 1 Improvements (To Re Included in Lolnpoc IXWRP Upgrade Project) ... 8-13
8.8.2 Stage 2 l~nprovements (Optional Items) .................................................................... 8-14
8.9 Preluninary Cost Estimate ......................................................................................................... 8-16
8.9.1 Stage 1 Improvements .................................................................................................. 8-16 .................................................................................................. 8.9.2 Stage 2 Improvements 8-16
CHAPTER 9 INSTRUMENTATION AND CONTROL SYSTEhi (Thf 7) ................................... 9-1
................................................................................................................................... 9.1 Introduction 9-1 ......................................................................................................... 9.1.1 Project Background 9-1
9.1.2 Objectives ......................................................................................................................... 9-1
9.2 Evaluation of Instrumentation and Controls Requirements .................................................. 9-1
9.2.1 Field Instrumentation ..................................................................................................... 9-1
9.2.2 Control Room Instrumentation .................................................................................... 9-2
9.2.3 Networking ....................................................................................................................... 9-2
9.2.4 SCXDA Architecture ...................................................................................................... 9-2
.......................................................................................... 9.2.5 PLCISCADA Programming 9-7
9.2.6 Instrumentation Power Supply ...................................................................................... 9-7
9.3 Recommendations ......................................................................................................................... 9-7
9.3.1 Recommended Improvements ...................................................................................... 9-7
. . ...................................................................................... 9.3.2 Prehrmnary Construction Cost 9-8
.................................... CI-IXPTER 10 MICROTURBINE COGENERATION SYSTEM (TM 8) 10-1
10.1 Project Background ..................................................................................................................... 10-1 .............................................................................................. 10.1.1 Digester Gas Production 10-1
10.1.2 Existing Electrical System ............................................................................................ 10-1 ..................................................................................................................................... 10.2 Objectives 10-2
10.3 Microturbine Alternatives ...................................................................................................... 10-2 .................................................................................................... 10.3.1 Technology Review 1 0 - 2
.................................................................................................. 10.4 System Sizing and Alternatives 10-4
10.4.1 Digester Gas Available for Cogeneration ................................................................ 10-4
10.4.2 Plant Heating Requirements ........................................................................................ 10-4
....................................................................................... 10.4.3 Comparison of Alternatives 10-12 .............................................................................................................. 10.5 Economic Evaluation 1 0 - 13
................................................. 10.5.1 Cost to Purchase Electric Power and Natural Gas 10-1 3 ....................... 10.5.2 Cost to Generate Electric Power from the Cogeneration System 10-1 3
.......................................................................................... 10.5.3 Electric Generation Costs 10-1 5
10.6 Recommendations ..................................................................................................................... 10-1 6
CONTENTS (continued) vi
APPENDIX A
XPPENDIX B
APPENDIX C
APPENDICES
MINUTES OF THE MEETINGS
PRELIhlINXRY COST ESTIMATE
IIEPLIICEMEN'T O F INFLUENT PUMPS
(Alternative A . Existing Pumping Station)
APPENDIX D REPIACEMEN'S OF INFLUENT P U ~ S
(illternative B . New Pumping Station)
XPPENDIX E
XPPENDIX F
INFLUENT FLOW MEASUREMENT
(MGD ADFM Velocity Profiler)
\'ACTOR TRUCK UNLOADING STATION
(Lakeside Septage Acceptance Unit)
TABLES
Thls Included in Report ............................................................................................................... 1-3 Design Criteria for Kecommended Pumping Station .............................................................. 1-5 Design Criteria for Aerated Grit Removal 'Tank ................................................................... 1-6 Secondary Treatment Design Criteria ............................................................................... 1-10 Design Criteria ........................................................................................................................... 1-15 Effluent Filter Design Criteria ................................................................................................... 1-21 UV Disinfection System Design Criteria .............................................................................. 1-25
......................................................................................... Existing Solids Processing Facilities 1-27 Solids Projections ........................................................................................................................ 1-29 Dissolved Air Flotation Thickening Design Criteria ............................................................. 1-30 Summarizes the Cost of the Recommendations ..................................................................... 1-39
Recommended Design Cntena ................................................................................................. 1-41
Preliminary Estimate of Probable Construction Cost ............................................................. 2-1 Summary Breakdown of Anticipated Bid Price by Process Area ........................................... 2-2
........................................................................................................................... Cost Comparison 2-3
...................................................................................... Existing Influent Pumping Faches(a) 1-2
............................................................................ Proposed Influent Pumping Design Criteria 3-3 Proposed Aerated Grit Removal Tank Design Criteria ....................................................... 3-10 Comparison of Conceptual Construction Costs .................................................................... 3-12
CONTENTS (continuedl vii
No.
TABLES (continued)
Page
Secondary Treatment Design Criteria ........................................................................................ 4-7 Projected Sludge Production ................................................................................................ 4 1 0 Secondary Treatment Design Criteria ..................................................................................... 4 1 6
.................................................................................................. Discharge Perinit hletals Limits 5-3 Design Catena ............................................................................................................................... 5-8
Effluent Filter Design Criteria ..................................................................................................... 6-6 ........................................................................................................ Budgetaiy Equipment Costs 6-9
Alternative U\Y7 Disinfection Systems Under Consideration ................................................ 7 1 UV Disinfection System Design Criteria ............................................................................. 7 1 1 O&hl Costs for Various UV Disinfection Systems ............................................................... 7 1 4
Existing Solids Processing Faciltties ........................................................................................... 8-2 Solids Projections .......................................................................................................................... 8-3 Dissolved ilk Flotation Thckening Design Criteria .......................................................... 8 - 6 Stage 2 Sludge Lagoon Design Criteria (To Achieve Class A in Lagoons) ........................ 8-12 Solids Handling Fachties Design Criteria Summary .............................................................. 8-1 5 Summary of Estimated Construction Costs for Stage 2 Solids Improvements ................. 8-16
Prehninary Cost Estimate for Alternative 1 ......................................................................... 10-7 Preliminary Cost Estimate for Alternative 2 ......................................................................... 10-1 1 Preliminary Cost Estimate of Alternative 3 ........................................................................... 10-1 2 Comparison of Alternatives ..................................................................................................... 10-1 2 Cost per kW-hr Electric Generation ...................................................................................... 10-1 6
FIGURES
Page
. ............................................................................................................................ 1.1 -1 Grit Tank Plan 1-4
1.3.1 Secondary Treatment Process Schcmatic ............................................................................... 1-1 2
1.4.1 'Tertia1-y Elocculators/Cla~fier Layout ..................................................................................... 1-1 7
1.4.2 Chemical Storage and Feed Area .............................................................................................. 1-1 8
1.5.1 Proposed Filters/UV Disinfcction Building Layout .......................................................... 1-22
1.8.1 Existing Seivice and Generation Single Line Diagram ......................................................... 1-34
1.1 1.1 Flow Diagram ............................................................................................................................. 1-47
1.1 3.1 Site Plan ........................................................................................................................................ 1-48
....................................................................................................................... 1 . 1 3.1 Hydraulic Profile 1 - 4 9
CONTENTS (continuedl
FIGURES (continued)
2.4.1 Project Schedule ........................................................................................................................ 2-4
3.8.1 Conceptual Layout of Headworks Fachties ............................................................................ 3-13
Historical Influent and Effluent Flow ..................................................................................... 4-3 Diurnal Influent Flow Pattern ..................................................................................................... 4-4 Historical Influent Chemical Oxygen Demand (COD) .......................................................... 4-5 Historical Influent Total Suspended Solids (TI'SS) ................................................................ 4-5 Historical Influent Volatde Suspended Solids (VSS) ............................................................... 4-6 Historical Influent and Xinbient Temperatures ....................................................................... 4-8 I-Iistorical Influent pH .................................................................................................................. 4-8 Secondary Treatment Process Schematic ............................................................................ 4-11 Secondaly Clarifier Design Features ........................................................................................ 4-15
5.61 Recommended Process Schematic for hietal Removal ........................................................... 5-6
.......................................................................... 8.4.1 Dissolved Xlr Flotation Thickener Schematic 8-5
8.4.2 Typical Dz-\FTs with Idow Profile Covers .................................................................................. 8-7
9.2.1 Proposed Scada Network Diagram ............................................................................................ 9-3
............................................................................................................ 10.3.1 Microturbine Schematic 10-3
10.4.1 Two Ingersoll Rand MT70 Microturbines Power Builchng - Partial Plan .......................... 10-6
10.4.2 Three Capstone C30 Microturbines Power Buildmg - Partial Plan .................................... 10-9
..................................................... 10.4.3 One Elhot blicroturbine Power Building - Partial Plan .I 0.1 0
February 3005
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