CITY OF VALLEJO FINISHED WATER PUMP STATION ELECTRIFICATION PROJECT PRELIMINARY DESIGN REPORT. FINAL December 2015

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1 This document is released for the purpose of information exchange review and planning only under the authority of Peter Briggs von Bucher, 12/11/2015, State of California, PE No It is not to be used for bidding, permit, or construction purposes. CITY OF VALLEJO FINISHED WATER PUMP STATION ELECTRIFICATION PROJECT PRELIMINARY DESIGN REPORT FINAL December YGNACIO VALLEY ROAD, SUITE 300 WALNUT CREEK, CALIFORNIA P F pw://carollo/documents/client/ca/vallejo/7784b10/deliverables/pdr/pdr.docx

2 CITY OF VALLEJO FINISHED WATER PUMP STATION ELECTRIFICATION PROJECT PRELIMINARY DESIGN REPORT TABLE OF CONTENTS Page No. LIST OF ABBREVIATIONS... LOA INTRODUCTION Outstanding Items for Final Design BASIS OF DESIGN SUMMARY TV PUMPS AND PIPING DESIGN CONCEPTS Overview of Existing System Hydraulics Pump Selection GRID PUMPS AND PIPING PROVISIONS ELECTRICAL DESIGN CONCEPTS New Power Requirements for the FWPS Electrification Project Electrical Service Evaluation Existing Power Distribution in the FWPS Variable Frequency Drives and VFD Rated Pump Motors Standby Power Requirements for the FWPS FWPS Electrical Room Recommended Electrical Improvements INSTRUMENTATION AND CONTROL DESIGN CONCEPTS TV Pump Controls TV Pump Instrumentation SEISMIC ASSESSMENT HVAC FIRE PROTECTION ADDITIONAL FUTURE IMPROVEMENTS IMPLEMENTATION Phased Implementation Construction Narrative for Phase COST ESTIMATE Estimate Class December DRAFT i

3 12.2 Estimate Structure Estimate Methodology Assumptions APPENDIX A APPENDIX B APPENDIX C APPENDIX D SPECIFICATION LIST DRAWING LIST CONSTRUCTION COST ESTIMATE PRELIMINARY PROJECT SCHEDULE LIST OF TABLES Table 1 PDR Basis of Design Summary... 4 Table 2 Advantages and Disadvantages of Pump Alternatives... 9 Table 3 New Power Requirements for FWPS Table 4 Construction Cost Estimate Summary Table 5 Phase 2 Deferred Costs Table 6 Combined Baseline vs. Phased Project Costs LIST OF FIGURES Figure 1 Trans-Vallejo System with New Horizontal Split-case Pumps... 8 TECHNICAL MEMORANDUMS TM - 1: HYDRAULIC ANALYSIS AND PUMP SELECTION TM - 2: SEISMIC ASSESSMENT TM - 3: LOAD AND RELIABILITY STUDY DRAWINGS VOLUME 2 - PRELIMINARY DESIGN DRAWINGS December DRAFT ii

4 City Of Vallejo LIST OF ABBREVIATIONS The following abbreviations are used in this document: ABBREVIATION BAAQMD CBC CFD FHWTP FT FWPS HI I/O LCA MCC mgd PDR PLC TDH TM TV VFD WBS DESCRIPTION Bay Area Air Quality Management District California Building Code Computational Fluid Dynamics Fleming Hill Water Treatment Plant Feet Finished Water Pump Station Hydraulic Institute Input/output Life Cycle Analysis Motor Control Center Million Gallons per Day Preliminary Design Report Programmable Logic Controller Total Discharge Head Technical Memorandum Trans-Vallejo Variable Frequency Drive Work-Based Structure December DRAFT LOA-1

5 CITY OF VALLEJO PRELIMINARY DESIGN REPORT 1.0 INTRODUCTION The Finished Water Pump Station (FWPS) is a critical component of the water system infrastructure for the City of Vallejo (City), as it is needed to deliver nearly all of the potable water from the Fleming Hill Water Treatment Plant (FHWTP) to the City's residents and businesses. The pump station currently consists of seven natural gas engine-driven pumps. Four of the pumps supply the Trans-Vallejo (TV) zone, while the other three pumps supply the Grid Zone. The two zones interconnect at various points in the distribution system and supply a number of tributary pressure zones. However, the existing engine-driven pumps do not comply with current air quality regulations as governed by the Bay Area Air Quality Management District (BAAQMD). The City and the BAAQMD entered into a Compliance and Settlement Agreement on November 26, Per the agreement, the City will need to cease operation of the pump station engines, and remove the engines from operation on or before January 1, To avoid the complete loss of the pump station, the FWPS Electrification Project will replace the existing engines and pumps with new electric motor-driven pumps to comply with the City s Compliance and Settlement Agreement. Per direction from the City, this project will be implemented in two phases, with each phase adding two new TV pumps and their associated electrical and auxiliary equipment. Specifically, Phase 1 of the project consists of the following elements: Replacement of two pumps that supply the TV zone with new electric motor-driven pumps. Removal of all existing engines and associated exhaust piping, fuel lines, and panels. Replacement and rearrangement of the suction and discharge piping for the TV pumps. Addition of new walkways in the FWPS for accessing the pumps. Addition of a motorized valve actuator at the North TV branch pipeline in the yard. Seismic assessment and structural upgrade of the FWPS. Addition of new VFDs for each new pump. December DRAFT 1

6 Addition of a new switchgear and Motor Control Center (MCC) in the FWPS. These will be connected to the existing plant main generator. Upsizing the existing 1,000 gallon fuel tank for the main plant generator to accommodate 48 hours of run-time under full load. Addition of a Remote I/O panel in the FWPS. Relocation of existing PLC panel in the FWPS. Relocation of existing sampling panel and instruments in the FWPS. Building modifications to include a new electrical room for housing the new electrical equipment and control panels. Connecting second backwash pump to the standby power supply. PG&E service load application for load increase. Phase 1 of the project is scheduled to be substantially complete on January 2nd, 2018, meeting the BAAQMD settlement compliance date. Phase 2 of the project is assumed to commence shortly after the completion of Phase 1 construction. Phase 2 of the project consists of the following elements: Addition of two more TV pumps to the FWPS, for a total of four TV pumps. VFDs, switchgears, MCCs, and cables associated with the two additional TV pumps. Branch piping and valves associated with the two additional TV pumps. The purpose of the Preliminary Design Report (PDR) is to provide a summary of the proposed improvements and the technical analysis and basis for these recommendations. To provide the reader with sources of additional information and detail, this document includes references to the following technical memorandums (TMs) associated with this project: Technical Memorandum 1 (TM-1) - Hydraulic Analysis and Pump Selection. Technical Memorandum 2 (TM-2) - Preliminary Seismic Evaluation. Technical Memorandum 3 (TM-3) - Load and Reliability Study. December DRAFT 2

7 1.1 Outstanding Items for Final Design The PDR presents the basis of design and preliminary design concepts for each element of the project. Many elements require further development in the final design. The following is a list of outstanding items requiring further development for final design: CFD modeling Surge analysis and surge mitigation strategies Geotechnical investigation New slab in FWPS Pipe penetrations in the FWPS Pipe supports HVAC design for electrical room Layout of generator fuel tank Temporary power for clearwell pumps during construction Addition of second backwash pump to standby power Ductbank sections Conduit routing Pump control strategy Remote I/O panel and programming Commissioning and testing requirements 2.0 BASIS OF DESIGN SUMMARY The basis of design for the Project is summarized in Table 1. December DRAFT 3

8 Table 1 PDR Basis of Design Summary Finished Water Pump Station Electrification Project City of Vallejo Design Element Item Value Unit Pump Station Capacity Trans-Vallejo (TV) Pumps in FWPS Maximum Flow 32 MGD Firm Build-out Capacity 1 25 MGD Phase 1 Capacity MGD Capacity during power outages Number of Pumps 2 Design Flow Rate Per Pump 16.6 MGD 8.3 MGD Design TDH 133 FT Type of Pump Horizontal Split-case Control Type VFD Number of VFDs 2 No. of Pulses 18 Note: (1) Capacity of build-out scenario of four new TV pumps with one pump out of service. (2) Capacity of two TV pumps to be installed in Phase 1 of the project. These design criteria are consistent with the City's historic total maximum day demand of 25 mgd, and total master planned (through 2035) maximum day demand of 32 mgd discussed in TM-1. While it is typical for the firm capacity to equal the future maximum day demand (i.e. 32 mgd), the City also has two pumps on the treatment plant clearwell which can be used in case one or two of the FWPS pumps are out of service. Therefore, the FHWTP potable water distribution system as a whole, will have a firm capacity that exceeds 32 mgd after build-out, while the firm capacity of the FWPS will be 25 mgd. The clearwell pumps will be operated as needed until Phase 2 is constructed. Note, while these criteria are consistent with total historic and total projected flows, this pump configuration differs from the existing configuration in that all flow from the FWPS will be pumped through the TV Zone rather than being split between the TV Zone and the Grid Zone. The Grid Zone will be fed from the TV Zone through pressure reducing valves instead of being fed directly. As discussed in TM-1, historic operations and projected demands show substantial flows through the Grid Zone (Historic: 1.1 mgd average, 4.5 mgd 99th percentile; Projected: 9.4 mgd average). This new configuration was selected by the City to allow greater flexibility in the event that the clearwell, and hence the clearwell pumps, have to be bypassed following a seismic event. If the clearwell is taken out of service, the City would still have a firm capacity of 25 mgd. December DRAFT 4

9 Additional pumps may be added for the Grid Zone in the future. While the average day demand for the Grid Zone is projected to be 9.4 mgd, per City staff, restrictions in the distribution system limit the amount of flow that can be pumped there from the FWPS. If distribution system improvements are made, installing new Grid Zone pumps may become more attractive to the City. 3.0 TV PUMPS AND PIPING DESIGN CONCEPTS 3.1 Overview of Existing System The FWPS is gravity fed by the Fleming Hill clearwell (10.89 MG) through a 42" pipeline. In the event that the clearwell is taken out of service, the FWPS can also receive water directly from the chlorine contact basin through the 42" clearwell bypass pipeline. Upon entering the pump station, the flow can branch to the TV Zone pump header or the Grid Zone pump header, after which the flow is pumped to the TV and Grid Zones through separate pipelines. The Grid Zone pipeline further branches into the East Vallejo Grid and the West Vallejo Grid pipelines. The TV Zone pipeline branches into the North TV and South TV/Swanzy pipelines. The TV Zone can also be serviced by the electric-tv pumps, which reside on top of the clearwell. The electric TV pipeline from the clearwell pumps converges with the TV pipeline from the FWPS just outside of the pump station. Reference Drawing D01 in Volume 2 of the PDR for more details. There are several interconnection points between the Grid and TV Zone systems, two of which reside immediately to the south of the pump station. The interconnections are controlled by manual valves and allow the TV pumps to feed the Grid Zone when the valves are open. Pressure-reducing valves on each of the East Vallejo Grid and West Vallejo Grid pipelines decrease the higher TV pressure down to the Grid pressure. 3.2 Hydraulics A detailed discussion of the TV Zone hydraulics can be found in TM-1. Figure 1 shows the pump curves for potential new horizontal split-case pumps plotted against a range of system curves for the TV Zone. The figure shows system curves for three scenarios: 1. High Head Scenario - High pipe friction factor, low clearwell water surface elevation ( FT), and high system demand pressure (319 FT). 2. Average Head Scenario - Moderate pipe friction factor, median clearwell surface elevation ( FT), and TV Zone design pressure (292 FT). 3. Low Head Scenario - Low pipe friction factor, high clearwell water surface elevation ( FT), and low system demand pressure (262 FT). December DRAFT 5

10 The pump curves represent 1, 2, 3, or 4 pumps in operation over their range of operating speeds. The pump selection is preliminary and should be fine-tuned during final design. As illustrated by Figure 1, under typical conditions three pumps will be operated to achieve the current TV Zone max flow of 25 MGD at 292 FT elevation pressure, while a fourth pump can be operated to achieve the 2035 Maximum Day Demand (MDD) of 32 MGD from the Water Master Plan. The design flows for the new pumps are substantially higher than historic maximum flows through the TV Zone pumps (18.3 mgd per TM-1); therefore, the velocity in the aboveground suction and discharge headers in the pump station will increase if changes aren't made. The Hydraulic Institute (HI) standard for water velocity in pump piping is 8 ft/sec in the suction pipeline to the pumps. At 25 mgd, the velocity in the existing 20-inch suction header and 24-inch discharge header is ft/sec and ft/sec respectively. Therefore, these pipes will be replaced with new 30-inch headers resulting in a velocity of 7.88 ft/sec at the firm capacity of 25 mgd. The piping layout for the TV pumps is modified to improve pump intake hydraulics and reduce headloss. A new tee will be installed in the existing 42" PW line from the clearwell just east of the pump station. This tee will feed the new 30" TV suction header. The flow is then divided into four 18" pump headers that enter the pump station from the east side. After the TV pumps and associated valves, the flow converges in a new 30" discharge header that exits the pump station through the existing southeast air intake. The new 30" piping is then connected to the existing 24" TV main just south of the pump station. The system curves in Figure 1 account for these changes. Reference drawing M01 in Volume 2 of the PDR for the new piping plan. The new piping layout increases the footprint of the aboveground TV piping in the FWPS. To facilitate access to the pumps and valves between the piping manifolds, a new aluminum walkway will be installed over the 30" discharge piping. Stairs or ships ladders will be installed from the walkway, leading down to each pump. In addition, a bridge crane will be installed for lifting pumps and valves in and out of the pump manifold. The bridge crane will be suspended from the existing I-beams used for the existing overhead lifts Surge analysis The substantial increase in flow to the TV zone from the FWPS (18.3 mgd to 32 mgd) increases the potential for pressure surges to be created during power outages or other events that interrupt power to the pumps. Furthermore, conversion from natural gas-driven engines to electric motors increases the chance that all operating pumps will experience a sudden shutoff simultaneously (i.e. a power outage will shut off all electric motors, while gas engines would keep running). Therefore, a surge analysis should be conducted during final design to identify the requirements for surge protection at the FWPS. December DRAFT 6

11 3.2.2 Computational Fluid Dynamics (CFD) Modeling Per standard of HI, physical modeling is suggested for pumps over 5000 gpm. While CFD is not explicitly permitted to replace physical modeling by HI, it is a generally accepted approach in the water industry to use CFD in lieu of physical modeling. A physical model or CFD model should be developed during final design to verify that the proposed suction piping meets HI design criteria. December DRAFT 7

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13 Figure 1- Trans-Vallejo System with New Horizontal Split-case Pumps (Flowserve 250LNN in Trim) TV -Zone Average Day Demand 12.4 MGD TV-Zone Max Day Demand 17.5 MGD Current Max: 25 MGD Total 2035 Master Plan Flow: 32 MGD Max Speed: 1800 RPM 1 Pump 2 Pumps 3 Pumps 4 Pumps 11 FT Reservoir, 319 FT Pressure High Friction Factor Head (ft) 15 FT Reservoir, 292 FT Pressure Medium Friction Factor FT Reservoir, 261 FT Pressure Low Friction Factor TV Zone (H) TV-292 TV Zone (L) % Speed TV Pumps Flow (gpm)

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15 3.3 Pump Selection An alternatives comparison using life cycle analysis (LCA) between horizontal split-case pumps and vertical turbine pumps was conducted, and is detailed in Appendix A of TM-1. Each type has various pros and cons related to efficiency, constructability, and maintenance. The findings of the LCA are as follows: Vertical turbine pumps would save approximately $5,000 per year in energy costs. Horizontal split-case pumps would save approximately $250,000 in capital costs. Horizontal split-case pumps would save approximately $239,000 over a 20 year life span, largely due to lower capital costs and lower assumed maintenance costs. In addition, the advantages and disadvantages of each alternative are presented in Table 2. Table 2 Advantages and Disadvantages of Pump Alternatives Finished Water Pump Station Electrification Project City of Vallejo Alternative Horizontal Split-case pumps Vertical Turbine Pumps Advantages Easy to maintain and inspect. Straightforward construction and installation. Slightly more efficient. Same type of pump as clearwell pumps. More flexibility in achieving optimal intake conditions. Disadvantages Occupies a larger footprint in the pump station. More expensive equipment. Narrower operating range Some construction and schedule risk in the installation of the pump and barrel in an existing building. Requires crane for removal of pump for servicing and overhauls. Based on the advantages and the life cycle costs, the replacement of the existing TV pumps with new horizontal split-case pumps is recommended. 4.0 GRID PUMPS AND PIPING PROVISIONS The Grid Zone is designed as a 212 pressure zone. There has been interest in supplying the grid zone without pumping. Since the water surface elevation at the clearwell is below the design pressure of the Grid Zone, it is expected that some pumping will be required for the Grid Zone in the future, unless the pressure in the zone is lowered. The FWPS December FINAL 9

16 Electrification Project will remove the existing Grid pumps and engines, and will leave space for future low-head, high-flow pumps. The Grid pump suction and discharge headers will remain in place in the FWPS. In addition, the new switchgear and MCC that are added in Phase 2 of the project will be sized to accommodate up to three future grid pumps. It is expected that the Grid Zone demand will be supplied by the new TV pumps through the existing inter-connections, until new Grid pumps are installed. 5.0 ELECTRICAL DESIGN CONCEPTS 5.1 New Power Requirements for the FWPS Electrification Project Table 3 provides a summary of the new pump power requirements. Preliminary selections of the new TV pumps indicate that they will require 250 horsepower (HP) motors. Potential future Grid pumps will likely require 50 HP to 75 HP motors. Spares are provided in the MCC for future Grid pumps. Table 3 New Power Requirements for FWPS Finished Water Pump Station Electrification Project City of Vallejo Item HP New/Existing/Future? On Standby? PMP TV New - Phase 1 Yes PMP TV New - Phase 1 Yes PMP TV New - Phase 2 No PMP TV New - Phase 2 No PMP Grid Future (1) Yes PMP Grid Future (1) No PMP Grid Future (1) No Roof Fan #1 2 Existing Yes Roof Fan #2 2 Existing Yes Roof Fan #3 2 Existing Yes Roof Fan #4 2 Existing Yes Lighting Panel - New replaces existing Yes Lighting Panel - New replaces existing No Electrical Room AHU 5-10 New - Phase 1 Yes Notes: (1) For future loads, spares will be provided in the new MCCs. December FINAL 10

17 5.2 Electrical Service Evaluation Utility service to the FHWTP is provided by Pacific Gas and Electric Company (PG&E). A PG&E supplied pad mounted 12kV - 480/277 3-phase transformer is located outside the Switchgear and Generator building. The transformer is rated for 1500 kva per City staff. To accommodate the new loads, the City has started a service size increase application with PG&E. During this process, PG&E will determine if this transformer needs to be increased in size based on the existing peak load and added loads in the FWPS. 5.3 Existing Power Distribution in the FWPS An existing SquareD MCC is located in the FWPS along the north wall. This MCC contains buckets for the roof vents in the FWPS, a lighting panel for the pump station, and a panel for the pump engine starters. The MCC is currently fed from MCC-S3 in the Generator and Switchgear building. The FWPS MCC is estimated to be over 40 years old. At this age it has outlived its useful life, and Carollo recommends replacing it with new MCCs, with starters and breakers located in a clean electrical room. The roof fan buckets and lighting panel will be moved to the new MCCs. To meet the new electrical demand in Table 3, two switchgears will be provided, one for the standby loads and one for the non-standby (normal) loads. Similarly, a standby MCC and a normal MCC will be provided. 5.4 Variable Frequency Drives and VFD Rated Pump Motors The new TV pumps will be on variable frequency drives (VFDs). VFD control allows the operator greater flexibility and can reduce energy costs, as the pumps can be ramped up or down based on demand. Carollo standard design includes inverter rated pump motors and shaft bearing harmonic current protection for VFD driven motors. 18-pulse VFDs are recommended for loads of 100 HP or greater to minimize harmonics on the power system, and they are specified to meet IEEE 519 standard recommended maximum harmonic levels. 5.5 Standby Power Requirements for the FWPS TM-3 provides a discussion of the load and reliability for FWPS standby capacity. A comparison of the alternatives between using the existing 1,000 kw generator (Alt. 1), and procuring a new dedicated generator (Alt. 2) is discussed in the TM. A summary of findings and recommendations from TM-3 is as follows: The existing standby generator is 1000 kw and has a fuel tank of 1,000 gallons. During the Draft PDR Workshop on October 29, 2015, a decision was made to upgrade the fuel tank to accommodate 48 hours of run-time under full load. December FINAL 11

18 A recent power outage showed that the current standby running load is about 200 kw. This may not capture all the intermittent loads such as the backwash pumps. The total generator related cost of Alternative 1 is estimated to be $113,000. The total generator related cost of Alternative 2 is estimated to be $336,000. During the Draft PDR Workshop on October 29, 2015, a decision was made to proceed with Alternative 1. The PDR electrical design drawings are based on Alternative 1. Different options for providing additional standby power provisions for the FWPS via temporary portable generators are discussed in TM-3. During the Draft PDR Workshop, a decision was made to provide a manual transfer switch in the nonstandby switchgear to provide this connection. Ozone generation equipment will remain off of backup power. 5.6 FWPS Electrical Room A new electrical room inside the FWPS will be built to house the new electrical equipment. Enclosing the electrical equipment in a separate room helps to keep equipment clean and adds an additional layer of security. The electrical room will be built at the Southwest corner of the FWPS. There will be two exits, a double door leading inside the FWPS and a single exit to the yard, as a second exit is required per the electrical code. A new set of stairs will be installed from the outside exit down to the yard. 5.7 Recommended Electrical Improvements Recommended electrical improvements are as follows: Phase 1: Add new ductbank and associated electrical manholes from the Generator and Switchgear Building to the FWPS. Include spare conduits for Phase 2 improvements. Add a new electrical room in the FWPS for housing new electrical equipment. Add new standby 2000A, 480V switchgear (SDS-2) in the FWPS electrical room. The new switchgear will connect to standby bus on the main electrical switchgear in the Generator and Switchgear Building. Add a new standby MCC (MCC S-6) in the FWPS electrical room. Upsize existing 1,000 gallon generator fuel-tank to accommodate 48 hours of runtime under generator full load. December FINAL 12

19 Phase 2: Add a new normal switchgear (NDS-1) for non-standby loads. Add a new MCC (MCC N-4) for non-standby loads. 6.0 INSTRUMENTATION AND CONTROL DESIGN CONCEPTS This sections describes the following instrumentation and controls improvements in the FWPS: VFD Pump Controls. Pump Protection Pressure Switches. PLC and Remote I/O. 6.1 TV Pump Controls The pumps will be pressure controlled to maintain a pressure setpoint at the discharge of the pump header. The PLC will determine the number of pumps to operate based on the pressure setpoint and measured flow. The pump station contains an existing PLC (CP-22-1). In lieu of moving the existing Pump Station PLC to the new electrical room, it will be left in place to minimize cost and complications during construction of the new pumps. A new remote I/O panel to the PLC will be included in the new electrical room. The existing HMI panel, located at existing PLC (CP-22-1) panel, will be programed to control and monitor the new remote I/O panel in the electrical room. The City will program the existing servers to monitor the added TV pumps and the added remote I/O in the electrical room. The existing control system software is a Rockwell RS View Supervisory Edition. Both the City and their system integrator Telstar have copies of the existing programming which will require modifications by the City. 6.2 TV Pump Instrumentation The existing TV zone flowmeter will remain in place at the current location in the yard. Pressure transmitters will be located in the 30" suction and discharge headers. Pressure gauges will be mounted on the outlet of each pump discharge for field readings. In addition, a high pressure switch will be provided on the discharge piping of each pump. The high pressure switch protects the pump against deadhead or blockage conditions that throttle the pump beyond normal operating pressures. A low pressure switch will be added on the suction side of the pump header to protect the pumps against running dry. Both pressure switches shall be hardwired into the Variable Frequency Drive to stop or inhibit pump December FINAL 13

20 starting when abnormal pressure condition is sensed. Vibration switches are not recommended for pumps of this size. 7.0 SEISMIC ASSESSMENT A preliminary seismic evaluation was conducted for the Finished Water Pump Station (FWPS) for the City of Vallejo in accordance with the Seismic Evaluation and Retrofit of Existing Buildings, ASCE which is referenced by the California Building Code (CBC) TM 2 provides a detailed discussion of this assessment. In summary, the retrofit recommendations include: Strengthening existing roof girder to wall connections by adding bent plates. Replacing the majority of the floor slab and tying the floor slab into the footing. Based on preliminary calculations, the existing wall footing should be tied into the floor slab. In addition, it is recommended that the new floor slab be thickened to support the new pumps and piping. Additional structural improvements may be require to accommodate equipment and piping supports, wall penetrations of piping, and the addition of a bridge crane. It is recommended to conduct a geotechnical investigation during final design. The findings presented in TM-2 are based on assumed lateral earth pressures and will be verified when site specific geotechnical information becomes available. 8.0 HVAC The four existing roof ventilation fans in the FWPS will be retained to provide ventilation in the pump station. The new electrical room in the pump station will have a separate ventilation system using air from the pump room. Pulling air from the pump room to ventilate the electrical room is desirable as the cool water piping in the room keeps the air temperature lower than the outdoor ambient temperature. An access cage ladder will be installed to provide access to the AHU. The temperature design criteria are: Outdoor temperatures: 25 to 110 degrees Fahrenheit. Indoor temperature: Process areas: 45 to 110 degrees Fahrenheit. Electrical room: 45 to 95 degrees Fahrenheit. 9.0 FIRE PROTECTION Based on a review of the 2013 California Building Code and 2013 California Fire Code, the FWPS can be classified as an F-1 (factory and industrial) occupancy. The building is not December FINAL 14

21 required to have an automatic sprinkler system per the building code based on the square footage of the pump station. With the removal of engines and fuels from the pump station, the risk of fire in the building is reduced. Heat and smoke detectors shall be added in the building as discussed during the Preliminary Electrification Design Meeting held on September 02, The detectors shall notify the Plant Control System when triggered. A fire alarm panel with connections to the fire department will not be provided. Portable fire extinguisher cabinets shall be provided near the north and south exits. The Fire Marshall shall be consulted during final design to confirm that all fire and life safety requirements are met ADDITIONAL FUTURE IMPROVEMENTS The section lists some additional future improvements that relate to the FWPS and were requested by various plant staff during meetings and site visits, but are currently not included in this project due to budgetary or sequencing constraints. These improvements should be revisited in the future to determine whether they should be included in Phase 2 of the project. New Grid Pumps. Additional Grid and TV yard piping improvements. Grid zone distribution system pipeline rehabilitation. Additional yard lighting. New indoor LED light fixtures IMPLEMENTATION 11.1 Phased Implementation During the Draft PDR Workshop held on October 29, 2015, the City indicated that they would like to split the implementation of the project into two phases. A two phased approach to implementing the FWPS Electrification Project would minimize the initial capital cost of the project, while still bringing the pump station into compliance with BAAQMD regulations. The goal of the first phase (Phase 1) would be to remove the existing TV pumps and engines, and install two new electric motor-driven pumps. The distribution system demand would then be met using the two existing clearwell TV pumps and the two new TV pumps. December FINAL 15

22 Phase 2 would add two additional TV pumps so that the FWPS can supply the entire system demand even if the clearwell is bypassed. The advantages of a phased approach are: Reduced near-term cash flow required to fund the project (i.e. minimizes initial capital cost of the project). Additional time to secure project financing for Phase 2 of the project. More comprehensive total project (Phase 2 of the project may include additional improvements such as yard piping modifications or new Grid pumps, that would not be included in a single phase project due to schedule and budget constraints). Disadvantages of the phased approach are: Increased total project cost due to additional design, mobilization/demobilization, overhead, and bid expenses. The phased approach would involve constructing most of the infrastructure improvements in Phase 1 of the project, but would only procure and install two out of the four TV pumps and their associated electrical equipment. The remaining two TV pumps and their electrical equipment would be installed in Phase Construction Narrative for Phase 1 Bidding of Phase 1 is scheduled to begin in May 2016, with an anticipated bid opening in late June 2016 and a notice to proceed in August A full project schedule for Phase 1 is presented in Appendix D of the PDR. The construction sequencing of the Phase 1 construction can be organized into four segments. The major construction activities in each segment are summarized as follows: Segment 1:Pump station seismic improvements and electrical yard work (August - November 2016): Prepare and review submittals for long-lead equipment such as the pumps, switchgear, MCCs, and VFDs. Strengthen roof connections. Install electrical ductbank from the Generator and Switchgear building to the FWPS. Install new conduits coming into the FWPS electrical room. December FINAL 16

23 Install generator fuel tank. Install valve vault and actuator at North TV branch. Segment 2: Mechanical improvements and electrical room (December April 2017): Shutdown and demolish existing TV pumps and engines. The TV pumps will be offline from the period after demolition of the existing engine up to the testing of the new pumps. It is assumed that the clearwell electric TV pumps will be operated during the period the FWPS TV pumps are offline. This period will be during the low demand season (December through April). The contractor will be responsible to provide a portable standby generator on-site for the clearwell pumps during this period. This generator will be used during power outages. A manual transfer switch will be provided at the clearwell pump VFDs for this connection. If additional capacity is needed, temporary bypass pumping may be required. Replace floor slab. Install and test new TV piping. Installation of the tee for the new TV header and the removal of the existing TV header will require the entire FWPS (TV and Grid Zones) to be offline temporarily. A new isolation valve will be provided on the TV suction header to isolate the TV zone from the Grid zone so the Grid zone pumps can continue operation during the installation of the new TV pumps and piping. Construct new electrical room. Pump manufacturing and factory testing. Electrical equipment manufacturing and factory testing. Segment 3: Installation of pumps and electrical equipment (May August 2017): Install TV pumps. Install switchgears, VFDs, MCCs, and Remote I/O panel. Install HVAC for electrical building. Segment 4: Testing and commissioning (September January 2, 2018): Test pumps and electrical systems. Demolish Grid pumps and engines. Conduct final inspection. Complete record drawings. December FINAL 17

24 The target final completion date for Phase 1 construction is January 2nd, 2018, meeting the BAAQMD agreement compliance date. Phase 2 construction is anticipated to start shortly after the completion of Phase 1, within 2-3 years COST ESTIMATE An opinion of probable construction cost has been prepared for the FWPS Electrification Project based on the drawings and design criteria presented in the PDR submittal. The detailed worksheets can be found in Appendix C of the PDR. A summary of the cost estimate is presented in Table 4. This table includes the total project cost (both Phase 1 and Phase 2) if implemented at the same time. December FINAL 18

25 Table 4 Construction Cost Estimate Summary 1 Finished Water Pump Station Electrification Project City of Vallejo Element Description % Total 01 General Conditions $394, Seismic Upgrades $97, Mechanical $1,331, Yard Improvements $411, Standby Power $189, E&IC $1,130,000 Total Direct Cost $3,552,000 Combined Markups 70% $2,488,000 Total Estimated Construction Cost $6,039,000 Note: (1) The cost estimate herein is based on our perception of current conditions at the project location. This estimate reflects our professional opinion of accurate costs at this time and is subject to change as the project design matures. Carollo Engineers have no control over variances in the cost of labor, materials, equipment; nor services provided by others, contractor's means and methods of executing the work or of determining prices, competitive bidding or market conditions, practices or bidding strategies. Carollo Engineers cannot and does not warrant or guarantee that proposals, bids or actual construction costs will not vary from the costs presented as shown. Using a phased approach, the City can defer some of the improvements and their associated costs to Phase 2 of the project. The Phase 2 deferred costs are presented in Table 5. However, there would be additional mobilization/demobilization, escalation, and bidding costs associated with a two-phased approach. These additional costs are shown in Table 6. December FINAL 19

26 Table 5 Phase 2 Deferred Costs Finished Water Pump Station Electrification Project City of Vallejo Item Cost (Including Markups) (2) 250 HP Horizontal Split-case pumps $663,000 (2) 250 HP 18-pulse VFDs $114,000 Check valves and isolation valves for 2 pumps $115,000 Piping for 2 pumps $40,000 Non-standby Switchgear (NDS-1) $408,000 Non-standby MCC (N-4) $43,000 Associated cables for 2 pumps $40,000 TOTAL $1,423,000 Table 6 Combined Baseline vs. Phased Project Costs 1 Finished Water Pump Station Electrification Project City of Vallejo Element Combined Baseline Phase 1 Phase 2 Estimated Construction Cost $6,039,000 $4,616,000 $1,423,000 Additional mobilization, demobilization, bid, and escalation 2 costs - - $430,000 Total Project Cost $6,039,000 $6,469,000 Percentage of Total Project Cost 100% 71% 29% Notes: (1) Costs are in 2016 dollars. (2) The escalation cost assumed that Phase 2 construction would start in February 2018 and conclude in October If the construction of Phase 2 is later than these dates, then escalation will need to be adjusted accordingly. (3) The cost estimate herein is based on our perception of current conditions at the project location. This estimate reflects our professional opinion of accurate costs at this time and is subject to change as the project design matures. Carollo Engineers have no control over variances in the cost of labor, materials, equipment; nor services provided by others, contractor's means and methods of executing the work or of determining prices, competitive bidding or market conditions, practices or bidding strategies. Carollo Engineers cannot and does not warrant or guarantee that proposals, bids or actual construction costs will not vary from the costs presented as shown. December FINAL 20

27 12.1 Estimate Class The PDR drawings were used to generate quantity takeoffs for each process area. As such, this cost estimate would be considered a Class 3 estimate by the Association for the Advancement of Cost Engineering. A Class 3 estimate is considered a budget level estimate and has the following characteristics: Project scope and detail between 10 and 40 percent completion. Prepared using semi-detailed unit costs and assembly-level line items (such as buildings on a square-foot basis). End use of the estimate is for determining project feasibility. Actual bids are expected to fall between +30 percent and -20 percent of the Total Estimated Construction Cost Estimate Structure The structure of the cost estimate is broken down into the following components: Direct Costs Includes all costs associated with labor, materials, and equipment necessary for the construction of each facility and process area, including all costs associated with mobilization and demobilization. These are considered hard costs that have a tangible end product (e.g., pipes), and are accounted for in the detailed cost estimate sheets. In the summary estimate, the direct costs are shown as Total Direct Cost. Markups Includes all costs that are not readily seen in the end product but are costs included with the contractor s bids. The markups included in this estimate are: Estimation Contingency: 30% General Contractor Overhead, Profit & Risk: 15% Escalation to Mid-Point: 5.4% (Assume 4% annual inflation escalated to April 2017, compounded monthly) Sales Tax: 4.3% on direct cost (Assume half of the direct cost is taxable) Bid Market Allowance: 5.0% Direct costs are organized according to a Work Breakdown Structure (WBS) established for this estimate. The WBS includes six elements, with each element having its own detailed cost estimate. For information on specific items included for each element, refer to the takeoff sheets in Appendix C. December FINAL 21

28 12.3 Estimate Methodology These estimates were prepared using Carollo s cost estimating model, which is built using quantity takeoffs and unit costs for materials and equipment. These unit costs are derived from internal databases (e.g., R.S. Means and Richardson s database) for materials and installation of common construction items (piping, concrete, etc.). Quotes have been obtained for large pieces of equipment in excess of $10,000, such as the TV pumps. The estimate includes direct labor, equipment, and subcontractor costs associated with construction materials and equipment. Labor, equipment, and subcontractor costs for materials of construction are presented in the detailed estimates as composite costs. These composite costs are calculated using crew listings and labor hours published by R.S. Means Assumptions Some assumptions have been required for the formulation of this cost estimate. Process area and line item specific assumptions are documented in the attached quantity takeoff and unit cost development sheets. Additional assumptions are as follows: Project delivery will be conventional design-bid-build. The project will be competitively bid, with bid prices presented as lump sums. Bids will be developed based on current material pricing and labor rates and are not to include any allowances for changes, extra work, unforeseen conditions, or other unplanned costs. This estimate assumes a minimum of four responsive bidders. A decrease in the number of bidders may lead to an increase in bid price, while an increase in the number of bidders may lead to a decrease in bid price. The project will not be required to adhere to EPA American Iron and Steel provisions for Drinking Water State Revolving Fund funded projects. These provisions may significantly increase the cost of piping and valves. All work, unless specifically stated otherwise, will be performed in 8-hour shifts with standard working hours of 7 AM through 5 PM, Monday through Friday. December FINAL 22

29 Preliminary Design Report APPENDIX A SPECIFICATION LIST

30

31 VALLEJO, CALIFORNIA FLEMING HILL WATER TREATMENT PLANT FINISHED WATER PUMP STATION ELECTRIFICATION PROJECT CONTRACT/TECHNICAL SPECIFICATIONS PDR SUBMITTAL TABLE OF CONTENTS DIVISION 00 BIDDING REQUIREMENTS, CONTRACT FORMS, AND CONDITIONS OF THE CONTRACT SECTION NO. TITLE GENERAL SECTION A SECTION B SECTION C SECTION D SECTION NO. DESCRIPTION OF PROJECT GENERAL REQUIREMENTS WAGE AND EQUIPMENT RATES CONSTRUCTION DETAILS AND TECHNICAL SPECIFICATIONS DIVISION 01 GENERAL REQUIREMENTS TITLE WORK RESTRICTIONS SUBMITTAL PROCEDURES ALTERATION PROJECT PROCEDURES SELECTIVE SITE DEMOLITION REGULATORY REQUIREMENTS QUALITY CONTROL SPECIAL TESTS AND INSPECTIONS PRODUCT REQUIREMENTS COMMISSIONING AND PROCESS START-UP CLOSEOUT PROCEDURES OPERATION AND MAINTENANCE DATA SEISMIC DESIGN CRITERIA WIND DESIGN CRITERIA SECTION NO. TITLE DIVISION 03 - CONCRETE EPOXY BONDING REINFORCING BARS AND ALL THREAD RODS IN CONCRETE CONCRETE WORK

32 GROUTING EPOXIES SECTION NO. TITLE DIVISION 04 - MASONRY EPOXY BONDING REINFORCING BARS AND ALL THREAD RODS IN MASONRY MASONRY ACCESSORIES CONCRETE UNIT MASONRY SECTION NO. TITLE DIVISION 05 - METALS MECHANICAL ANCHORING AND FASTENING TO CONCRETE AND MASONRY METAL FABRICATIONS SECTION NO. DIVISION 07 - THERMAL AND MOISTURE PROTECTION TITLE JOINT SEALANTS SECTION NO. TITLE DIVISION 08 - OPENINGS HOLLOW METAL DOORS AND FRAMES DOOR HARDWARE SECTION NO. TITLE DIVISION 09 - FINISHES HIGH-PERFORMANCE COATINGS SECTION NO. TITLE SIGNAGE DIVISION 10 - SPECIALTIES FIRE PROTECTION SPECIALTIES SECTION NO. DIVISION 23 - HEATING, VENTILATING, AND AIR CONDITIONING TITLE HVAC SYSTEMS TESTING, ADJUSTING, AND BALANCING HEATING, VENTILATING, AND AIR CONDITIONING CONTROLS METAL DUCTWORK DUCTWORK ACCESSORIES AIR HANDLING UNIT

33 DIVISION 26 - ELECTRICAL SECTION NO. TITLE LOW VOLTAGE MOTORS UP TO 500 HP VOLT OR LESS WIRES AND CABLES WIRE CONNECTIONS CONDUITS BOXES DUCT BANKS ELECTRICAL IDENTIFICATION ELECTRICAL SYSTEM STUDIES CONDUIT SCHEDULE FIELD ELECTRICAL ACCEPTANCE TESTS DRY-TYPE TRANSFORMERS LOW VOLTAGE SWITCHGEAR PANELBOARDS LOW VOLTAGE MOTOR CONTROL CENTERS WIRING DEVICES LOW VOLTAGE MOLDED CASE CIRCUIT BREAKERS VARIABLE FREQUENCY DRIVES HORSEPOWER LIGHTING DIVISION 28 - ELECTRIC SAFETY AND SECURITY SECTION NO. TITLE FIRE ALARM AND SMOKE DETECTION SYSTEM DIVISION 31 - EARTHWORK SECTION NO. TITLE EARTHWORK SOILS AND AGGREGATES FOR EARTHWORK TRENCHING DEWATERING CONTROLLED LOW STRENGTH MATERIAL (CLSM) EXCAVATION SUPPORT AND PROTECTION

34 SECTION NO. DIVISION 32 - EXTERIOR IMPROVEMENTS TITLE PAVEMENT RESTORATION AND REHABILITATION ASPHALTIC CONCRETE PAVING DIVISION 33 - UTILITIES SECTION NO. TITLE PRECAST CONCRETE VAULTS SECTION NO. TITLE DIVISION 40 - PROCESS INTEGRATION COMMON WORK RESULTS FOR GENERAL PIPING PIPE IDENTIFICATION PIPING SYSTEMS TESTING PIPE SUPPORTS PREFORMED CHANNEL PIPE SUPPORT SYSTEM STEEL PIPING VALVES MANUAL ACTUATORS ELECTRIC ACTUATORS BUTTERFLY VALVES CHECK VALVES AIR AND VACUUM RELIEF VALVES PROCESS CONTROL AND INSTRUMENTATION SYSTEMS GENERAL REQUIREMENTS CONTROL STRATEGIES SPECIFIC CONTROL STRATEGIES CONTROL SYSTEMS - PROGRAMMABLE LOGIC CONTROLLERS HARDWARE CONTROL SYSTEMS: NETWORK MATERIALS AND EQUIPMENT CONTROL SYSTEMS - PANELS, ENCLOSURES, AND PANEL COMPONENTS MAGNETIC FLOWMETERS PRESSURE/VACUUM MEASUREMENT - GAUGES PRESSURE/VACUUM MEASUREMENT - SWITCHES TESTING, CALIBRATION, AND COMMISSIONING PLC I/O LISTING SCHEDULES - FIELD INSTRUMENTS

35 DIVISION 43 - PROCESS GAS AND LIQUID HANDLING, PURIFICATION, AND STORAGE EQUIPMENT SECTION NO. TITLE AXIALLY-SPLIT CENTRIFUGAL PUMPS DIVISION 46 - WATER AND WASTEWATER EQUIPMENT SECTION NO. TITLE COMMON WORK RESULTS FOR MECHANICAL EQUIPMENT EQUIPMENT IDENTIFICATION MECHANICAL EQUIPMENT TESTING

36

37 Preliminary Design Report APPENDIX B DRAWING LIST

38

39 Finished Water Pump Station Drawings List Drawing List Sheet Number Drawing Number Title PDR 90% 1 G01 GENERAL COVER SHEET, LOCATION MAPS X X 2 G02 DRAWING INDEX X X 3 G03 GENERAL NOTES, LEGEND, AND SYMBOLS X X 4 G04 ABBREVIATIONS X X 5 G05 GENERAL MECHANICAL SYMBOLS X X 6 G06 SITE PLAN X X 7 T01 TYPICAL DETAILS TYPICAL DETAILS - CIVIL/MECHANICAL X 8 T02 TYPICAL DETAILS - CIVIL/MECHANICAL X 9 T03 TYPICAL DETAILS - MECHANICAL X 10 T04 TYPICAL DETAILS - MECHANICAL X 11 T05 TYPICAL DETAILS - STRUCTURAL X 12 T06 TYPICAL DETAILS - STRUCTURAL X 13 T07 TYPICAL DETAILS - EI&C X 14 T08 TYPICAL DETAILS - EI&C X 15 T09 TYPICAL DETAILS - EI&C X 16 T10 TYPICAL DETAILS - EI&C X 17 D01 DEMOLITION YARD PIPING AND EQUIPMENT X X 18 D02 PUMP STATION FLOOR X 19 D03 PUMP STATION - PLAN X X 20 D04 SECTIONS AND DETAILS X 21 C01 CIVIL CIVIL PLAN - PAVING AND GRADING X 22 C02 YARD PIPING X X 23 S01 STRUCTURAL PUMP STATION STRUCTURAL FLOOR PLAN X 24 S02 PUMP STATION STRUCTURAL ROOF PLAN X 25 S03 PUMP STATION SECTIONS AND DETAILS X 26 S04 PUMP STATION SECTIONS AND DETAILS X MECHANICAL 27 M01 PUMP STATION PLAN X X 28 M02 PUMP STATION SECTIONS X X 29 M03 PUMP STATION SECTIONS AND DETAILS X ELECTRICAL 30 E01 LEGEND AND SYMBOLS X X 31 E02 ABBREVIATIONS X X 32 E03 SITE PLAN X X 33 E04 DUCT BANK SECTIONS X 34 E05 WTP MAIN ONE LINE DIAGRAM X X 35 E06 FINISHED WATER PUMP STATION SWITCHGEAR ONE-LINE DIAGRAM X X 36 E07 FINISHED WATER PUMP STATION MCC ONE-LINE DIAGRAM X X 37 E07 MCC ELEVATIONS X 38 E08 MCC ELEVATIONS X 39 E09 TABLES AND SCHEDULES X 40 E10 TABLES AND SCHEDULES X 41 E11 PUMP STATION POWER AND CONTROL PLAN X 42 E12 PUMP STATION LIGHTING AND GROUNDING PLAN X 43 E13 YARD POWER AND CONTROL PLAN X INSTRUMENTATION 44 N01 SYMBOLS AND ABBREVIATIONS I X X 45 N02 SYMBOLS AND ABBREVIATIONS II X X 46 N03 SYMBOLS AND ABBREVIATIONS III X X 47 N04 SYMBOLS AND ABBREVIATIONS IV X X 48 N05 SCHEMATIC SYMBOLS X X 49 N06 SAMPLE LOOP DRAWING X X 50 N07 CONTROL SYSTEM BLOCK DIAGRAM X (Pump Station Only for PDR) X 51 N08 CONTROL SCHEMATICS X 52 N09 P&ID - TV PUMPS NO.1 AND NO.2 X X 53 N10 P&ID - TV PUMPS NO.3 AND NO.4 X X 54 N11 P&ID X 55 N12 P&ID X

40

41 Preliminary Design Report APPENDIX C CONSTRUCTION COST ESTIMATE

42

43 PROJECT SUMMARY Estimate Class: 3 Project: FWPS Electrification Project PIC: Ken Wilkins Client: City of Vallejo PM: Peter von Bucher Location: Vallejo, CA Date: December 18, 2015 Zip Code: By: George Chin Carollo Job # 7784B.10 Reviewed: Peter von Bucher NO. DESCRIPTION TOTAL 01 General Conditions $394, Seismic Upgrades $97, Mechanical $1,331, Yard Improvements $411, Standby Power $189, E&IC $1,130,000 TOTAL DIRECT COST $3,552,000 Contingency 30.0% $1,066,000 Subtotal $4,618,000 General Contractor Overhead, Profit & Risk 15.0% $693,000 Subtotal $5,311,000 Escalation to Mid-Point 5.4% $287,000 Subtotal $5,598,000 Sales Tax (Based on 8.63%/2 on Direct Cost) 4.3% $153,000 Subtotal $5,751,000 Bid Market Allowance 5.0% $288,000 TOTAL ESTIMATED CONSTRUCTION COST $6,039,000 The cost estimate herein is based on our perception of current conditions at the project location. This estimate reflects our professional opinion of accurate costs at this time and is subject to change as the project design matures. Carollo Engineers have no control over variances in the cost of labor, materials, equipment; nor services provided by others, contractor's means and methods of executing the work or of determining prices, competitive bidding or market conditions, practices or bidding strategies. Carollo Engineers cannot and does not warrant or guarantee that proposals, bids or actual construction costs will not vary from the costs presented as shown. x