Hopewell Water Treatment Plant Virginia’s 1 st Design-Build Water Treatment Plant Retrofit Project Dave Johnson – PC Construction Michael Youshock – VA American Water Laurence Zimmermann – Gannett Fleming Ryan Ural – American Water
VAW Hopewell - Overview VAW is a subsidiary of American Alexandria Water, the largest investor owned water/wastewater utility in the US. Provides water service to Prince William Warsaw approximately 57,000 customers Operations in 4 districts in VA: Richmond Alexandria, Prince William, Warsaw & Hopewell. HOPEWELL
VAW Hopewell Service to 9,300 customers, incl several large industries & Fort Lee military base. Treatment capacity: 36 MGD Plant produces potable and non-potable (industrial) grades of water Source water: Appomattox River (tidal tributary of James River)
Hopewell Water System • Unique Aspects: • Plant produces 2 grades of water, potable and non-potable (industrial). • Numerous facilities operating nearing 100 years of service. • Tidal source water, widely varying raw water quality characteristics. • 6 Industrial customers use 80-85% of all water produced, wide swing in usage patterns. • Limited tolerance of service disruptions • Need for WTP Improvements: • Industrial wood tub filters at end of useful life, difficult to repair. • Potable plant operating at 12 mgd firm capacity during peak months. Plant produces 2 grades of water: potable (Domestic) & non-potable (Industrial) Numerous facilities operating, nearing 100 years of service. Tidal source water, widely varying raw water quality characteristics. 6 Industrial customers use 80-85% of all water produced. Wide swing in usage patterns & limited tolerance of service disruptions.
Need for Improvements Hopewell Water System • Unique Aspects: • Plant produces 2 grades of water, potable and non-potable (industrial). • Numerous facilities operating nearing 100 years of service. • Tidal source water, widely varying raw water quality characteristics. • 6 Industrial customers use 80-85% of all water produced, wide swing in usage patterns. • Limited tolerance of service disruptions • Need for WTP Improvements: • Industrial wood tub filters at end of useful life, difficult to repair. • Potable plant operating at 12 mgd firm capacity during peak months. Industrial wood tub filters at end of useful life, difficult to repair. Potable plant operating at 12 MGD firm capacity during peak months. Need additional space for office staff & maintenance facility. Existing operator’s laboratory outdated and not efficient.
Hopewell Water System • Unique Aspects: • Plant produces 2 grades of water, potable and non-potable (industrial). • Numerous facilities operating nearing 100 years of service. • Tidal source water, widely varying raw water quality characteristics. • 6 Industrial customers use 80-85% of all water produced, wide swing in usage patterns. • Limited tolerance of service disruptions • Need for WTP Improvements: • Industrial wood tub filters at end of useful life, difficult to repair. • Potable plant operating at 12 mgd firm capacity during peak months. REPLACEMENTS & UPGRADES IN AN ACTIVE WATER PLANT VERY TIGHT BUDGET – LARGE SCOPE OF WORK OLD FACILITY ( “This Old House” for Water Treatment Plants) PROJECT SCHEDULE & TIMING
Project Scope DOMESTIC SYSTEM Increase potable system capacity to 15 MGD reliable (18 MGD total) Upgrade sedimentation basins & install tube settlers Add 2 new domestic filters & 4 new GAC vessels Add 2.5 MG clearwell Add/replace high service pumps Chemical feed improvements Administration & maintenance building additions Control & instrumentation improvements INDUSTRIAL SYSTEM Demolition of Industrial Wood Tub Filters Replace existing wood tubs with 4 high rate multi-media filters Wastewater improvements
Project Scope – VAW Hopewell Admin building addition Demolish old lab, build new one Chemical feed improvements New 2.5 MG clearwell Demolish tub filters ADDED SCOPE: Repair sed basins & install tube settlers Increase emergency 4 new industrial filters Add & replace high service pumps generator power 2 new domestic filters 4 new GAC vessels
Why Design-Build? Design-Build would give the Owner flexibility to deal with the unique challenges of an aged facility, while keeping on schedule and budget. 1. Minimize project timeframe: Existing facilities failing & needed expansion of plant capacity. 2. Active WTP: Complex tie-ins required to minimize impact on operations Detailed coordination required from design to start-up.
Selection Process: RFQ sent to pre-qual list of engineers & contractors VAW/AW evaluated interested D/B teams. AW sent RFP to shortlisted teams. VAW/AW received proposals: costs & fees in separate sealed envelope Quals-based evaluation by Owner (with score card) Cost & Fees opened & evaluated. VAW/AW reached consensus on “best match” to project
Project Timeline June 2008 – American Water issues RFP July 2008 – Proposals received September 2008 – Notice of Award November 2008 – Notice to Proceed May 2009 – 60% Target Cost: $16.2M July 2009 – Groundbreaking Ceremony April 2011 – Substantial Completion June 2011 – Anticipated Final Completion December 2011 – Actual Final Completion*
Permitting Hurdles
Permitting Hurdles Virginia Waterworks Regulations 12VAC5-590-190. Permits. Construction permit issued by State Health Commissioner required prior to construction or modification of water infrastructure. 12VAC5-590-200. Procedure for obtaining a construction permit. Requires coordination between Owner, Engineer & VA Dept of Health (VDH) VAW’s project schedule was very ambitious with regard to start of construction & acquisition of permits.
Permit Coordination Meetings To assure timely acquisition of Permits, the Owner & D/B Team met with representatives of the Virginia Dept of Health (VDH) & the City of Hopewell These meetings allowed us to: a. Present the project to the permitting agencies b. Work with them to determine pitfalls & issues c. Establish a working relationship with specific individuals within the permitting agencies (useful when permitting questions arose)
VDH Meeting: Tube Settler Issue One potential pitfall identified by VDH related to the new tube settlers proposed for the domestic sed basin. Typically, the Department requires pilot testing to substantiate the requested design parameters. Discussion with VDH allowed VAW to provide documentation indicating similar installations with these ratings in support of the permit. Once provided, the documentation was accepted and this part of the project moved forward.
VDH Meeting: Two-Phased Permit During preliminary design phase, it was determined that substantial reductions in construction time could be achieved by obtaining the VDH permit in two phases: . The first would be for the 2.5 MG tank whose design required minimal time, along with reduced permit review time. With the tank permit submitted, the rest of the design was completed and submitted for permit approval. Early issuance of the tank permit allowed for its construction. Once complete, it allowed for longer plant outages that were useful during plant tie ins.
Design flexibility during construction with Design-Build: New Generator Well into the construction of the project, it was decided to improve the standby power supply system that was currently on site. A study was conducted to establish the size of the new generator, followed by purchase & installation of the unit. The D/B process gave the Owner a means of adding this to the project at a competitive price.
Flexibility during design with Design-Build: Industrial Filter Bldg Pilot filter testing of Industrial water resulted in the reduction of planned filters - from five to four.
Working with the contractor during design allowed for innovations & cost savings that would not have been possible using a “traditional” Design-Bid-Build delivery method
Examples of Cost & Schedule savings realized using D/B
2.5 MG Domestic Clearwell: Concrete instead of steel
Domestic Filter Bldg: Auger Cast Piles VALUE ENGINEERING OPPORTUNITY
Admin Office Building Addition: Subcontracting Non-Critical Work
Site Paving: Asphalt Reclamation
Throughout project: Steel Interior Piping
Tub Filter Bldg: Material Reclamation
Planned Treatment Plant Outages Improvements to the domestic sedimentation basin required the plant to continue to meet customer water demands while having approximately 50% of its pre-treatment capacity off line. All other process improvements were completed prior to initiating this outage. This included placing both the new domestic & industrial filters on-line prior to starting this work.
Project Successes D/B approach facilitated good partnership between all parties from beginning to end. Upgrades to operating facility fairly well coordinated with all parties Critical tie-ins completed with minimal impact on operations. Value added items identified throughout process, allowed for additional scope (generator). Project completed under budget & on schedule*.
Lessons Learned Plan the location of the Porta-Potty very carefully??
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