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2 7 0 0 Y G N A C I O V A L L E Y R O A D • S U I T E 3 0 0 • W A L N U T C R E E K , C A L I F O R N I A 9 4 5 9 8 • ( 9 2 5 ) 9 3 2 - 1 7 1 0 • F A X ( 9 2 5 ) 9 3 0 - 0 2 0 8 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL CITY OF MODESTO JENNINGS ROAD FACILITY TECHNICAL MEMORANDUM CANNERY SEGREGATION PUMP STATION OPERATIONAL EVALUATION FINAL MAY 2013 ---PAGE BREAK--- May 2013 i pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL CITY OF MODESTO JENNINGS ROAD FACILITY TECHNICAL MEMORANDUM CANNERY SEGREGATION PUMP STATION OPERATIONAL EVALUATION TABLE OF CONTENTS Page No. 1.0 PURPOSE 1 2.0 SUMMARY OF FINDINGS AND RECOMMENDATIONS 1 3.0 BACKGROUND 2 4.0 EVALUATION OF PUMP STATION AND OPERATIONAL CHALLENGES 5 4.1 Can Seg System Study 5 4.2 Site Visit and Field Evaluations 5 4.3 Review of Existing Data 6 4.4 Hydraulic Evaluation 8 5.0 RECOMMENDATIONS 11 5.1 Alternative A - Replacement of Existing Pumps with new Vertical Turbine Solids Handling pumps 11 5.2 Alternative B - Replacement of Existing Pumps with Axial Flow Propeller Pumps from Fairbanks Morse 14 5.3 Alternative C - Replacement of Existing Pumps with Axial Flow Propeller Pumps of Alternate Manufacturer 14 5.4 Additional Recommendations: 14 5.5 Cost Estimate 18 LIST OF TABLES Table 1 Comparison of Wet Well Design with HI Standards 8 Table 2 Cost Estimate Summary for Each Alternative 18 Table 3 Cost Estimate for Alternative A - VTSH Replacement and Upgrades 19 Table 4 Cost Estimate for Alternative A2 - VTSH Replacement and Upgrades – Owner Install Option 20 Table 5 Cost Estimate for Alternative B – Fairbanks Morse Axial Flow Pumps Replacement 21 Table 6 Cost Estimate for Alternative B2 – Fairbanks Morse Axial Flow Pumps Replacement – Owner Install Option 22 Table 7 Cost Estimate for Alternative C – Axial Flow Propeller Pumps and Upgrades – Alternative Manufacturer (Prime Pump Co.) 23 Table 8 Cost Estimate for Alternative C2 – Axial Flow Propeller Pumps and Upgrades – Alternative Manufacturer (Prime Pump Co.) – Owner Install Option 24 ---PAGE BREAK--- May 2013 ii pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL LIST OF FIGURES Figure 1 2008 – 2012 Cannery Segregation Daily Average Flow Rates 4 Figure 2 Cavitation and Corrosion Damage on Pump Components 7 Figure 3 Can Seg System and Existing Pump Curves 10 Figure 4 Alternative A: Fairbank Morse VTSH Pump Curves 13 Figure 5 Alternative B: Fairbanks Morse Axial Flow Pump Curves 16 Figure 6 Alternative C: Prime Pump Co. Axial Flow Pump Curves 17 LIST OF APPENDICES A - Existing Ingersoll-Dresser Pump Curves B - Desk Top Study Hydraulic Calculations C - Quotes And Manufacturer Curves ---PAGE BREAK--- May 2013 1 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL Technical Memorandum CANNERY SEGREGATION PUMP STATION OPERATIONAL EVALUATION 1.0 PURPOSE The purpose of this technical memorandum (TM) is to evaluate the Cannery Segregation (“Can Seg”) pump station for the City of Modesto, California, located at the Jennings Rd. Secondary Treatment Facilities site. The TM identifies possible causes for operational problems and recommendation for improvements to the pump station. 2.0 SUMMARY OF FINDINGS AND RECOMMENDATIONS The key findings and recommendations are summarized below: The Can Seg pump station consists of three equally sized pumps to achieve a firm capacity of 28 million gallons per day (mgd). Three equally sized pumps with a capacity each of 14 mgd were installed. Two pumps are designed for duty operation with one pump serving as a standby. One additional deck space is available for a future pump. The current average daily flows range between 13 to 18 mgd. As such, the installed pumps are oversized and running off their curve, causing vibrations and rough running conditions. The Can Seg flows have declined over recent years and have only exceed 20.3 mgd in two occasions over the last five canning seasons. As such, the firm capacity of the pump station should be reduced to from 28 mgd to 20.3 mgd. The standby pump should be programmed to switch on for additional capacity in the rare event that flows exceed 20.3 mgd. Many parameters in the wet well design at the Can Seg pump station differ from Hydraulic Institute (HI) standards for pump intake design. The approach flow characteristics at the pump bowls causes pump cavitation and pre-swirling of fine sand and grit at the pump intake. The pump bowl and impeller have been damaged both from cavitation and from abrasion and erosion caused by a high volume of fine sand and grit material present in the cannery waste. Long-term contact with low pH cannery waste leads to aggressive corrosion on the cast iron and steel components of the pump. The corrosion and pitting on these components is accelerated by the deterioration of the lining. The plant staff has been pulling the pumps out of the wet well annually to repair the pumps and to recoat the bowls and the pump columns. Pump impellers wear rings ---PAGE BREAK--- May 2013 2 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL and line shafts have been replaced and restored several times since installation in 1997. We recommend replacing the three existing pumps with three new vertical turbine solids handling pumps that have better flow characteristics for the current operating conditions. In addition, we recommend that the pumps be installed with open top confined inlet barrels to improve the hydraulic conditions at the pump intake. The estimated cost for the new pumps and inlets is $2.32 million. 3.0 BACKGROUND The Can Seg pump station at Jennings Road was placed in service in 1999. It is usually operated for about four months every year during the canning season (July through October). The pump station receives food process byproducts from the pump station located at the Sutter Avenue Primary Treatment Facility, and pumps to the irrigation mixing box at the Jennings Rd. site, where the food processing water is mixed with flow from the irrigation reservoir and sent to the ranchland at the Jennings Road site. The pump station currently has three 20-inch Vertical Turbine Solids Handling (VTSH) pumps model 20QMN- A manufactured by Ingersoll-Dresser Pumps (IDP). The pumps are each rated for 14 mgd (9,722 gallons per minute[gpm]) at 55 feet of total dynamic head (TDH) at 1,190 RPM. The pumps are equipped with 200 HP motors which are speed controlled using VFDs manufactured by Allan Bradley, Model 1336 Plus. The Can Seg pump station at Jennings Road was designed in June 1998 as part of the Ranch Cannery Pump Station and Force Main Project. At the time of design, numerous food process facilities and two major canneries fed into the Can Seg system. The original design accommodated for a future capacity of 42 mgd, which was envisioned to be achieved by increasing the size of the pump impellers and motor, and adding an additional pump. Since the time of design, the number of food processing plants in Modesto has decreased. One of the two major canneries that fed into the system during design is not longer in operation. As such, Can Seg flows have decreased significantly from the design firm capacity of 28 mgd to 15.2 mgd on average. Figure 1 shows the plot of daily average flow rates from the 2008 to the 2012 cannery seasons. In this time frame, the Can Seg flow rates is below 20 mgd for 98 percent of the time and have only exceeded 20.3 mgd on two days. In recent years, the City has encountered operational challenges with the Can Seg Pump Station at Jennings Road. Plant maintenance operators have noted that the pumps are experiencing vibration and require frequent costly annual maintenance. After the cannery season each year, the pumps are the lifted out of the wet well for repairs and maintenance work. When the pumps were taken out of service and disassembled, severe damages incurred by cavitation and corrosion were observed in the inlet bell, impeller, retaining bolt, ---PAGE BREAK--- May 2013 3 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL discharge head, and other pump components. According to staff, the pumps have been rebuilt three times within 10,000 hours. The plant maintenance operators have remediated problems with the shaft and flush bearing; however, damage from cavitation and corrosion has not been addressed. In addition, the pumps were observed by the plant staff to have harmonic problems where excess vibration occurs between 31-35 Hz. ---PAGE BREAK--- -5.0 0.0 5.0 10.0 15.0 20.0 25.0 30.0 7/5 7/25 8/14 9/3 9/23 10/13 Daily Average Flow Rate (MGD) Date Figure 1 2008 - 2012 Cannery Segregation Daily Average Flow Rates 2008 2009 2010 2011 2012 ---PAGE BREAK--- May 2013 5 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL 4.0 EVALUATION OF PUMP STATION AND OPERATIONAL CHALLENGES This section reviews the operational challenges for the Can Seg pump station and determines possible causes for the rough running conditions at the pump station based on site visit observations, existing data, and hydraulic analyses. 4.1 Can Seg System Study Carollo conducted a computer desk top hydraulic study of the Can Seg Pump Station. The construction drawings from Camp Dresser & McKee - CDM (Ranch Cannery Pump Station and Force Main Project – June 1998) were used as a basis to calculate the system head curves. The published pump curve data from the IDP shop drawings (Appendix A) were then superimposed on chart. The system TDH curves were based on cement mortar lined steel pipe, and three TDH curves were developed using three different assumptions for the friction factor (Hazen-Williams equation; C=130 “smooth new pipe”; C=120 rougher pipe lining”; and C=110 “rougher pipe lining”). In addition, we simulated highest lift conditions (low wetwell and high mixing box water surface elevation) and lowest lift to create a range of operating condition requirements that a pump or combination of pumps will need to meet (See Appendix B for detailed system curve calculations). Results are used to create the TDH curves for Figures 3 through 6. The hydraulic analysis on the existing pump station show that the existing pumps are not operating on their pump curves. A single pump operating at full speed is oversized for current conditions when the flow is between 8 and 14 mgd. When two pumps are operating in parallel, the pumps are better suited for the design firm capacity of 28 mgd at 55 feet. 4.2 Site Visit and Field Evaluations Plant O&M staff and Carollo conducted a field visit on September 27, 2012 to collect information during cannery season operating conditions, compare field dimensions with available record and shop drawings for the pump station and IDP pumps. A field meeting was held on the same day to review operational challenges and maintenance history with the City’s O&M staff. The O&M staff confirmed that the pumps have several difficulties including corrosion, cavitation, adverse inlet hydraulics, shaft misalignment, flush water quality, and vibrations. 4.2.1 Field Pump Test A field test to confirm the results from the desk top hydraulic study was conducted during the September 27, 2012 site visit. The butterfly valve (BRV101) immediately of the magnetic flow meter was incrementally closed to create an artificial resistance pressure ---PAGE BREAK--- May 2013 6 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL head and raise the system head requirement. At each interval, readings for pressure head, pump speed, wet well water level, and flow rate was recorded. Severe vibrations were observed when the valve is fully or mostly open. The vibrations diminished as the valve is incrementally closed. This test confirmed the findings of the desk top study which indicated that system head is significantly below the pump operating head and that the current pumps are oversized for current flow conditions. 4.3 Review of Existing Data 4.3.1 Review of Drawing/Layout Design drawings for the Can Seg P.S. were reviewed for consistency and some pertinent dimensions were compared with field measurements. The drawings appear to conform to field measurements and observations with the exception of the circular concrete openings on the Can Seg pump station deck, which are shown to be 42 inches on the drawings, but were measured to be about 33-inches in the field. 4.3.2 Review of Shop Drawing The submittal for the existing IDP pumps was reviewed to determine the material specification of the components, the coating specification, and the performance test curve. Submittal shows the components susceptible to cavitation and corrosion damage such as the impeller, diffuser bowl, and suction bell to be made of ASTM A48 cast iron. The original submitted coating is Polyamidoamine Epoxy that contains 69 percent volume solids. This solids content is less than the High Solids Epoxy that Carollo specifies for submerged pump components under similar conditions. Performance test curves for the IDP pumps show that all three pumps deliver more than 55 ft of total dynamic head (TDH) at 10,000 GPM (14.4 mgd) at full speed. However, discussions with the plant staff and hydraulic analysis indicates that only 20-32 ft of total discharge head is needed at normal operating flow rates, suggesting that the pumps are not suitably sized for current flows. 4.3.3 Review of Training Workshop Document The Training Workshop Document contains information about the different operating modes and the design criteria of Can Seg system. The document shows an initial station capacity of 28 mgd, which will later be expanded to an ultimate capacity of 42 mgd. However, according to staff, these predicted high flows are not seen in the recent cannery seasons and is not expected any time soon. 4.3.4 Summary of Data and Photos The Training Workshop Document and the performance pump test in the submittal both reveal that the TDH for the IDP pumps are much higher than the actual operating pressure head needed. This discrepancy results in operation that is outside of the pump curve, which ---PAGE BREAK--- May 2013 7 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL creates adverse flow conditions that may cause cavitation. Photos (Figure 2) taken in the field when the pumps are taken out of service confirm that intake bell, impellers, discharge head, and other components of the pump been significantly impaired by corrosion and cavitation. Figure 2 Cavitation and Corrosion Damage on Pump Components a) Intake bell corrosion and abrasion, note spiraling pattern from pre-swirling; b) Impeller edge eroded by cavitation and corrosion; c) Discharge head corrosion; d) Disintegration of pipe lining between discharge and check valve. b a c d ---PAGE BREAK--- May 2013 8 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL 4.4 Hydraulic Evaluation 4.4.1 Wet well design as compared to Hydraulic Institute standards Hydraulic Institute Standards for pump intake (HI 9.8) contains a series of geometrical guidelines aimed to minimize adverse hydraulic phenomena such as vortices, excessive pre-swirl at intake bell, and non-uniform flow at the impeller eye. The observed vibrations, cavitation, and abrasion damage may be caused or exacerbated by these adverse hydraulic phenomena at the intake. Comparisons of dimensions shown on design drawings and HI recommended dimensions reveal salient differences in many hydraulically sensitive parameters. These comparisons are summarized in Table 1. Table 1 Comparison of Wet Well Design with HI Standards Cannery Segregation Pump Station Evaluation City of Modesto Parameter HI Standard Actual Approach velocity entering wet well ≤2.0 ft/s Not measured, but calculated at 0.9 ft/s at 14 mgd. Velocity in channel ≤1.0 ft/s Not measured, but calculated at 1.1 ft/s at 14 mgd. Suction bell intake velocity 3.0-8.0 ft/s 2.2 ft/s at 8 mgd 3.9 ft/s at 14 mgd End wall clearance 24” 72” Floor clearance 9.6” – 16” 18” Influent Pipe Coaxial wetwell and free of flow disruption for eight pipe diameters Perpendicular to wetwell Anti-rotation baffle at the last pump none Note: HI recommended dimension calculations are based on inlet bell outside diameter of 32” The wet well geometry differs significantly from the recommended trench-type geometry in the HI standards. The HI trench-type wet well features an inlet above the suction bell and a wider section above the narrow trench, where the pump intake is situated. This layout reduces turbulence by slowing the velocity in the channel above the trench and directing flow downward into the trench. In comparison, in the existing pump station, the inlet is at the channel bottom and there is no trench to uniformly direct flow toward the suction bell. In addition, suction bell intake velocity ranges on the low side of the HI acceptable range for flows under 14 mgd, causing grit to swirl excessively at the pump intake. Furthermore, the ---PAGE BREAK--- May 2013 9 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL flow enters the wet well perpendicularly from the upstream 66-inch line and this may create additional turbulence in the wet well channel. These adverse hydraulic phenomena may be an exacerbating factor in causing cavitation and excessive vibrations. 4.4.2 Hydraulic Calculations In the desk top study, calculations were performed to evaluate a range of total dynamic head for different pipe friction factors and generate system curves. Dimensions and material specification listed in drawings were used for the friction calculations, while current alarm settings and daily average water levels in the pump station and irrigation mixing box were used to evaluate the actual static head. The performance test curves for the existing pumps are fitted on available data. The resulting analysis illustrating system and existing pump curves are shown on Figure 3. To verify the calculated system curves, additional field-testing was conducted based on two pumps operating in parallel on November 16, 2012. After calibrating for field elevations, the seven data points were then plotted against the calibrated system curves. The calibrated field data points fits closely with the average system curve (depicted by the green TDH graph on Figures 3 through Figure 3 shows that two current pumps running in parallel is capable of producing 21,000 gpm (30.2 mgd) at 52 feet, which is more than the specified designed firm capacity of 28 gpm at 55 feet TDH. This discharge head requirement in the original design appears to be based on the high friction scenario. However, available data and profile recording show that average flow rate and pressure head requirement have been much lower in the recent cannery seasons, as confirmed by the 2008 through 2012 cannery segregation flow data. Over the average range of operation, the pump curve at full speed is far above the system curve. Significant speed reduction using VFDs are required before the pump curve intersects the system curve. Furthermore, with a single pump in operation at full speed, the pump curves intersect the system curve at the tail end (right side of the curve), where rises sharply. This creates cavitation when exceed NPSHa. From these hydraulic calculations, it appears that existing pumps are not well sized for operation in the 8- to 14-mgd flow range, as the flow/head characteristics for the pumps is much larger than the system requirement. The field pump test conducted on September 27, 2012 confirmed the gap between the pump curve and the TDH system curves. The pump was observed to run smoother as the butterfly valve on the discharge line was incrementally closed to provide resistance head and raise the system curve. ---PAGE BREAK--- 0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 Head (ft) Flow (gpm) Figure 3 Can Seg System and Existing IDP Pump Curves S-curve High Head S-curve Normal Operating Head S-curve Low Head 11/16 Adjusted Test Points 1 Pump @ 100% Speed 2 Pumps @ 100% Speed 1 Pump @ 68% Speed 2 Pumps @ 72% Speed Low Wet Well Level, High Mix Box Level, Hazen-Williams C = 110. Normal Operating Head, Wet Well Level and Mix Box Level from Daily Average Readings from 1-Aug-12 to 30-Sep-12, C = 120. High Wet Well Level, Low Mix Box Level, C = 130. 12 MGD 6 MGD 20 MGD ---PAGE BREAK--- May 2013 11 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL 5.0 RECOMMENDATIONS 5.1 Alternative A - Replacement of Existing Pumps with new Vertical Turbine Solids Handling pumps Due to poor condition of the existing pumps and the salient decrease of cannery segregation flow rates in the recent years, we recommend replacing the existing Can Seg pumps with new Vertical Turbine Solids Handling pumps (VTSH) with open top confined barrel inlet that are suitably sized for current and future cannery waste flows. The pumps should be selected such that the following parameters are met: Pump dimensions are compatible with existing wet well dimensions. Pump curve intersects systems curve for current daily average flows between 13 to 18 mgd. Pump is operating on or near the best efficiency point for daily average flows Pump impeller, line shaft, suction bell, fasteners, and other components susceptible to corrosion are made of corrosion-resistant material. A quote for new 20-inch VTSH pumps with standard corrosion upgrade provided by JM Squared is included in Appendix C. The corrosion-resisting upgrade consists of nitronic 50 line shaft with ceramic coating on bearings, and epoxy coating and lining on pump components. In addition to these standard upgrades, we recommend that the impeller to be constructed of 316L stainless steel. The quoted pumps operate with 100 HP high efficiency motors as opposed to the current pumps that require 200 HP motors. These proposed new pumps are sized such that a single pump is sufficient to handle flow rates up to 10 mgd and that two pumps in operation will meet the new firm capacity of 20.3 mgd. The new pump curves are plotted with the existing system curves in Figure 4, which shows that the quoted pumps are smaller and have a steeper curve than the existing IDP pumps, making than more compatible with flows between 8 to 14 mgd. Two pumps are required to meet the new firm capacity of 20.3 MGD and an additional standby pump should be provided for redundancy. 5.1.1 Open Top Confined Barrel Inlets Carollo recommends that open top confined barrel inlets be installed around the intake of each pump to mitigate the effects of adverse hydraulic conditions such as vortices, grit- swirling, turbulence, flow rotation, and uneven flow distribution. The open top confined inlet is a hollow cylinder with flow guiding vanes that is installed around the pump intake. The confined inlets will reduce or eliminate the turbulence generated from the abrupt flow direction change at the wet well entrance. The confined inlets will also eliminate vortices, ---PAGE BREAK--- May 2013 12 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL pre-swirl at intake bell, and non-uniform flow at the impeller eye by directing flow from the top of the barrel uniformly downwards toward the suction bell of the pump. ---PAGE BREAK--- 0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 Head (ft) Flow (gpm) Figure 4 Alternative A: Fairbank Morse VTSH Pump Curves S-curve High Head S-curve Normal Operating Head S-curve Low Head 11/16 Adjusted Test Points 1 Pump @ 100% Speed 2 Pumps @ 100% Speed 1 Pump @ 68% Speed 2 Pumps @ 72% Speed Low Wet Well Level, High Mix Box Level, Hazen-Williams C = 110. Normal Operating Head, Wet Well Level and Mix Box Level from Daily Average Readings from 1-Aug-12 to 30-Sep-12, C = 120. High Wet Well Level, Low Mix Box Level, C = 130. 12 MGD 6 MGD 20 MGD ---PAGE BREAK--- May 2013 14 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL 5.2 Alternative B - Replacement of Existing Pumps with Axial Flow Propeller Pumps from Fairbanks Morse Axial flow propeller pumps with stainless steel propeller and bowl liner may be a suitable substitute for the existing VTSH pumps if both parameters outlined in section 5.1 for VTSH pump and the following conditions are met: The passing sphere size of the pump is larger than the size of the solids in the cannery and food processing water. There are no stringy solids in the cannery and food processing water that may clog and impair the impeller. Single stage axial flow propeller pumps tend have lower head capacities and stricter reliable operating ranges than VTSH pumps. If this alternative is chosen, care should be given to the selection of the pump such that the pump operates at or near the max speed under normal operating conditions. One model of Fairbanks Morse axial flow pump is plotted with the existing system curves in Figure 5. However, without adjustments, this particular model does not appear to be well suited for the system. Three pumps are required to meet the new firm capacity of 20.3 MGD and additional standby pump should be provided for redundancy. Open top confined inlet barrels are also recommended on the pump intake to mitigate adverse hydraulic conditions. 5.3 Alternative C - Replacement of Existing Pumps with Axial Flow Propeller Pumps of Alternate Manufacturer Axial flow propeller pumps from an alternate manufacturer with standard materials of construction, stainless steel propeller, and stainless steel bowl liner can be considered as a lower cost alternative than options A and B. Axial flow pumps from Prime Pump Co. is plotted with the existing system curve in Figure 6. Three pumps are required to meet the new firm capacity of 20.3 MGD and additional standby pump should be provided for redundancy. Open top confined inlet barrel is also recommended for this alternative to eliminate cavitation and abrasive erosion. 5.4 Additional Recommendations: In addition, we recommend the following improvements to the pump station: 1. Add an open top confined inlet barrel for each pump (whether new or refurbished pumps). 2. Install concrete support below the check valve on each pump discharge, which is currently unsupported. ---PAGE BREAK--- May 2013 15 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL 3. Coat the inside of the wet well with Enduraflex elastomeric coating to protect the concrete from corrosion. 4. Flush out wet well and replacing volume with freshwater or tertiary effluent at the end of the cannery season. Prolonged stagnant conditions with cannery waste rich in organic matter and low in pH cause corrosion. ---PAGE BREAK--- 0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 Head (ft) Flow (gpm) Figure 5 Alternative B: Fairbanks Morse Axial Flow Pump Curves S-curve High Head S-curve Normal Operating Head S-curve Low Head 11/16 Adjusted Test Points 1 Pump @ 100% Speed 2 Pumps @ 100% Speed 3 Pumps @ 100% Speed 1 Pump @ 68% Speed 2 Pumps @ 72% Speed 3 Pumps @ 72% Speed Low Wet Well Level, High Mix Box Level, Hazen-Williams C = 110. Normal Operating Head, Wet Well Level and Mix Box Level from Daily Average Readings from 1-Aug-12 to 30-Sep-12, C = 120. High Wet Well Level, Low Mix Box Level, C = 130. 12 MGD 6 MGD 20 MGD ---PAGE BREAK--- 0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 Head (ft) Flow (gpm) Figure 6 Alternative C: Prime Pump Co. Axial Flow Pump Curves S-curve High Head S-curve Normal Operating Head S-curve Low Head 11/16 Adjusted Test Points 1 Pump @ 100% Speed 2 Pumps @ 100% Speed 3 Pumps @ 100% Speed 1 Pump @ 68% Speed 2 Pumps @ 72% Speed 3 Pumps @ 72% Speed Low Wet Well Level, High Mix Box Level, Hazen-Williams C = 110. Normal Operating Head, Wet Well Level and Mix Box Level from Daily Average Readings from 1-Aug-12 to 30-Sep-12, C = 120. High Wet Well Level, Low Mix Box Level, C = 130. 12 MGD 6 MGD 20 MGD ---PAGE BREAK--- May 2013 18 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL 5.5 Cost Estimate A preliminary cost estimate based on provided quotes for the different alternative are summarized in Table 2. Two options, installation by contractor and installation by owner, are provided for each alternative. Detailed cost breakdown for each alternative and option is tabulated in Table 3 through Table 8. The cost estimates assume that the project is scheduled to be completed by mid-2014. Table 2 Cost Estimate Summary for Each Alternative Cannery Segregation Pump Station Evaluation City of Modesto Alternative Installation By Contractor Installation By Owner A – Fairbanks Morse VTSH (3 pumps) $2,325,000 $1,399,000 B – Fairbanks Morse Axial Flow Pumps (4 pumps) $1,324,000 $797,000 C – Prime Pump Co. Axial Flow Pumps (4 pumps) $1,208,000 $727,000 ---PAGE BREAK--- May 2013 19 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL Table 3 Cost Estimate for Alternative A - VTSH Replacement and Upgrades Cannery Segregation Pump Station Evaluation City of Modesto PROJECT SUMMARY Estimate Class: Class 5 Project: Can Seg P.S. Eval - ALTERNATIVE A PIC: Client: City of Modesto PM: JMP Location: Modesto, CA Date: May 1, 2013 Zip Code: 95358 By: GC Carollo Job # 9076A.00 Reviewed: JMP NO. DESCRIPTION Unit Cost Qty TOTAL 01 Fairbanks Morse VTSH Pump & Motor 250,000.00 $ 3 750,000 $ 02 Open Top Confined Inlets (316 SST) 25,000.00 $ 3 75,000 $ 03 316L SST Impeller and Corrosion Resistance Upgrades 62,000.00 $ 3 186,000 $ 04 100-HP VFD Replacement Allowance 36,250.00 $ 3 108,750 $ 05 Check Valve 39,000.00 $ 0 - $ 06 Check Valve Support 2,000.00 $ 3 6,000 $ 07 Wet Well Enduraflex Lining Allowance 40,000.00 $ 1 40,000 $ TOTAL DIRECT COST 1,165,750 $ Contingency 30.0% 349,725 $ Subtotal 1,515,475 $ General Contractor Overhead, Profit & Risk 18.0% 272,786 $ Subtotal 1,788,261 $ Escalation to Mid-Point 3.0% 53,648 $ Subtotal 1,841,908 $ Sales Tax 8.8% 162,088 $ Subtotal 2,003,996 $ Bid Market Allowance 0.0% - $ TOTAL ESTIMATED CONSTRUCTION COST 2,003,996 $ Engineering, Legal & Administration Fees 12.0% 240,480 $ Owner's Reserve for Change Orders 4.0% 80,160 $ TOTAL ESTIMATED PROJECT COST 2,324,636 $ 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. ---PAGE BREAK--- May 2013 20 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL Table 4 Cost Estimate for Alternative A2 - VTSH Replacement and Upgrades – Owner Install Option Cannery Segregation Pump Station Evaluation City of Modesto PROJECT SUMMARY Estimate Class: Class 5 Project: Can Seg P.S. Eval - ALTERNATIVE A2* PIC: Client: City of Modesto PM: JMP Location: Modesto, CA Date: May 1, 2013 Zip Code: 95358 By: GC Carollo Job # 9076A.00 Reviewed: JMP NO. DESCRIPTION Unit Cost Qty TOTAL 01 Fairbanks Morse VTSH Pump & Motor (typ. Of 3 Pumps) 250,000.00 $ 3 750,000 $ 02 Open Top Confined Inlets (316 SST) 25,000.00 $ 3 75,000 $ 03 316L SST Impeller and Corrosion Resistance Upgrades 62,000.00 $ 3 186,000 $ 04 100 HP VFD Replacement Allowance 36,250.00 $ 3 108,750 $ 05 Check Valve 39,000.00 $ 0 - $ 06 Check Valve Support 2,000.00 $ 3 6,000 $ 07 Wet Well Enduraflex Lining Allowance 40,000.00 $ 1 40,000 $ TOTAL DIRECT COST 1,165,750 $ Owner's Engineering, Legal, and Adminstration Fees, and Reserve 20.0% 233,150 $ TOTAL ESTIMATED PROJECT COST 1,398,900 $ *OWNER INSTALL OPTION 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. ---PAGE BREAK--- May 2013 21 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL Table 5 Cost Estimate for Alternative B – Fairbanks Morse Axial Flow Pumps Replacement Cannery Segregation Pump Station Evaluation City of Modesto PROJECT SUMMARY Estimate Class: Class 5 Project: Can Seg P.S. Eval - ALTERNATIVE B1 PIC: Client: City of Modesto PM: JMP Location: Modesto, CA Date: May 1, 2013 Zip Code: 95358 By: GC Carollo Job # 9076A.00 Reviewed: JMP NO. DESCRIPTION Unit Cost Qty TOTAL 01 Fairbanks Morse Axial Flow Pump & Motor 83,000.00 $ 4 332,000 $ 02 Open Top Confined Inlets (316 SST) 25,000.00 $ 4 100,000 $ 03 316L SST Impeller and Corrosion Resistance Upgrades - $ 4 - $ 04 100 HP -VFD Replacement Allowance 36,250.00 $ 4 145,000 $ 05 Check Valve 39,000.00 $ 1 39,000 $ 06 Check Valve Support 2,000.00 $ 4 8,000 $ 07 Wet Well Enduraflex Lining Allowance 40,000.00 $ 1 40,000 $ TOTAL DIRECT COST 664,000 $ Contingency 30.0% 199,200 $ Subtotal 863,200 $ General Contractor Overhead, Profit & Risk 18.0% 155,376 $ Subtotal 1,018,576 $ Escalation to Mid-Point 3.0% 30,557 $ Subtotal 1,049,133 $ Sales Tax 8.8% 92,324 $ Subtotal 1,141,457 $ Bid Market Allowance 0.0% - $ TOTAL ESTIMATED CONSTRUCTION COST 1,141,457 $ Engineering, Legal & Administration Fees 12.0% 136,975 $ Owner's Reserve for Change Orders 4.0% 45,658 $ TOTAL ESTIMATED PROJECT COST 1,324,090 $ 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. ---PAGE BREAK--- May 2013 22 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL Table 6 Cost Estimate for Alternative B2 – Fairbanks Morse Axial Flow Pumps Replacement – Owner Install Option Cannery Segregation Pump Station Evaluation City of Modesto PROJECT SUMMARY Estimate Class: Class 5 Project: Can Seg P.S. Eval - ALTERNATIVE B2* PIC: Client: City of Modesto PM: JMP Location: Modesto, CA Date: May 1, 2013 Zip Code: 95358 By: GC Carollo Job # 9076A.00 Reviewed: JMP NO. DESCRIPTION Unit Cost Qty TOTAL 01 Fairbanks Morse Axial Flow Pump & Motor 83,000.00 $ 4 332,000 $ 02 Open Top Confined Inlets (316 SST) 25,000.00 $ 4 100,000 $ 03 316L SST Impeller and Corrosion Resistance Upgrades - $ 4 - $ 04 100 HP VFD Replacement Allowance 36,250.00 $ 4 145,000 $ 05 Check Valve 39,000.00 $ 1 39,000 $ 06 Check Valve Support 2,000.00 $ 4 8,000 $ 07 Wet Well Enduraflex Lining Allowance 40,000.00 $ 1 40,000 $ TOTAL DIRECT COST 664,000 $ Owner's Engineering, Legal, and Adminstration Fees, and Reserve 20.0% 132,800 $ TOTAL ESTIMATED PROJECT COST 796,800 $ *OWNER INSTALL OPTION 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. ---PAGE BREAK--- May 2013 23 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL Table 7 Cost Estimate for Alternative C – Axial Flow Propeller Pumps and Upgrades – Alternative Manufacturer (Prime Pump Co.) Cannery Segregation Pump Station Evaluation City of Modesto PROJECT SUMMARY Estimate Class: Class 5 Project: Can Seg P.S. Eval - ALTERNATIVE C PIC: Client: City of Modesto PM: JMP Location: Modesto, CA Date: May 1, 2013 Zip Code: 95358 By: GC Carollo Job # 9076A.00 Reviewed: JMP NO. DESCRIPTION Unit Cost Qty TOTAL 01 Prime Pump Co. Axial Flow Pump & Motor 68,500.00 $ 4 274,000 $ 02 Open Top Confined Inlets (316 SST) 25,000.00 $ 4 100,000 $ 03 316L SST Impeller and Corrosion Resistance Upgrades - $ 4 - $ 04 100 HP -VFD Replacement Allowance 36,250.00 $ 4 145,000 $ 05 Check Valve 39,000.00 $ 1 39,000 $ 06 Check Valve Support 2,000.00 $ 4 8,000 $ 07 Wet Well Enduraflex Lining Allowance 40,000.00 $ 1 40,000 $ TOTAL DIRECT COST 606,000 $ Contingency 30.0% 181,800 $ Subtotal 787,800 $ General Contractor Overhead, Profit & Risk 18.0% 141,804 $ Subtotal 929,604 $ Escalation to Mid-Point 3.0% 27,888 $ Subtotal 957,492 $ Sales Tax 8.8% 84,259 $ Subtotal 1,041,751 $ Bid Market Allowance 0.0% - $ TOTAL ESTIMATED CONSTRUCTION COST 1,041,751 $ Engineering, Legal & Administration Fees 12.0% 125,010 $ Owner's Reserve for Change Orders 4.0% 41,670 $ TOTAL ESTIMATED PROJECT COST 1,208,432 $ 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. ---PAGE BREAK--- May 2013 24 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL Table 8 Cost Estimate for Alternative C2 – Axial Flow Propeller Pumps and Upgrades – Alternative Manufacturer (Prime Pump Co.) – Owner Install Option Cannery Segregation Pump Station Evaluation City of Modesto PROJECT SUMMARY Estimate Class: Class 5 Project: Can Seg P.S. Eval - ALTERNATIVE C2* PIC: Client: City of Modesto PM: JMP Location: Modesto, CA Date: May 1, 2013 Zip Code: 95358 By: GC Carollo Job # 9076A.00 Reviewed: JMP NO. DESCRIPTION Unit Cost Qty TOTAL 01 Prime Pump Co. Axial Flow Pump & Motor 68,500.00 $ 4 274,000 $ 02 Open Top Confined Inlets (316 SST) 25,000.00 $ 4 100,000 $ 03 316L SST Impeller and Corrosion Resistance Upgrades - $ 4 - $ 04 100 HP VFD Replacement Allowance 36,250.00 $ 4 145,000 $ 05 Check Valve 39,000.00 $ 1 39,000 $ 06 Check Valve Support 2,000.00 $ 4 8,000 $ 07 Wet Well Enduraflex Lining Allowance 40,000.00 $ 1 40,000 $ TOTAL DIRECT COST 606,000 $ Owner's Engineering, Legal, and Adminstration Fees, and Reserve 20.0% 121,200 $ TOTAL ESTIMATED PROJECT COST 727,200 $ *OWNER INSTALL OPTION 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. ---PAGE BREAK--- May 2013 1 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL City of Modesto APPENDIX A - EXISTING INGERSOLL-DRESSER PUMP CURVES ---PAGE BREAK--- ---PAGE BREAK--- ---PAGE BREAK--- ---PAGE BREAK--- ( PUMP PERFORMANCE ( ( TDH Eff I I I (FT) ('Is) I I INGERSOLL-DRESSER PUMP 120 90 I I I I This pump is designed I to deJ.iver: I I I 100 80 I , US GPM : 9722 I I I TDH : 55 (FT ) I I I RPM : 1190 I I I Eff iciency: 84\- 80 70 I I , I BHP : 162 I I : 29 (FT) I II I 60 60 I. I 5 " D:i.ameter So1id I I I '1 2 Van.e Impe11er I J I I II I I I 40 SO I I II I Dri.ver: Electric Motor I I I I I . , I I I I This curve shows the 20 40 I I expected heads and I II I I I efficiencies other I II at I I I ' " capacities, but this - I additional is II data 0 30 I I only approximate and I I is not guaran.teed" I I I II 20 I I I I I , I " . , I I I ~ 10 I I II . I , I I I I I I 0 0 10 20 30 40 50 60 70 80 90 100 110 Capacity Certified by: X (100 US GPM) Project: RANCH CANNERY PUMP STATION 20Q~-A Date : 10-9-98 Model No " Service: RAS PUMPS P101, P102 P104 Order No " SOO0841 E-ESOOO841 ---PAGE BREAK--- May 2013 2 pw://Carollo/Documents/Client/CA/Modesto/9076A00/Deliverables/Can Seg Pump Station Operation Eval FINAL City of Modesto APPENDIX B - DESK TOP STUDY HYDRAULIC CALCULATIONS ---PAGE BREAK--- Client: City of Modesto Project: Can Seg Pump Station Evaluation Job No: 9076A.00 General 1. Required Pumping Capacity 5. System Schematic Q (min) 4 mgd Basis: Conservative Assumption 36" Steel Cement Lined Pipe Q (startup) 8 mgd Basis: City Staff 66" CW (RCP) from Sutter Q (design) 28 mgd Basis: CDM Training Workshop 2. Process Fluid Cannery Waste from Sutter Primary Plant 3. Operational Criteria VFD Driven - Maintain an operator selectable flow setpoint GAT 101 HWL EL 47.50 2 Duty / 1 Standby LWL EL 39.50 4. System Background GAT 102 overflow weir at 4' from top GAT 103 Bypass to FFR The pump station receives cannery waste (CW) from Sutter Ave. Can Seg Pump Station, and pumps CW to the mixing box at the Jennings Rd. site, where the CW can be mixed with flow from the irrigation reservoir and sent to ranches at the Jennings Road plant site. The pump station currently has three 20” Vertical Turbine Solids Handling (VTSH) pumps model 20QMN-A manufactured by Ingersoll-Dresser Pumps (IDP). The pumps are each rated for 14 MGD (9,722 gpm) at 55’ TDH at 1,190 RPM and are equipped with 200 HP motors 2 4 1 Irrigation Mixing Box HWL EL 64.50 LWL EL 59.00 M ---PAGE BREAK--- Client: City of Modesto Project: Can Seg Pump Station Evaluation Job No: 9076A.00 Seg A1 P104 Pump Intake to Discharge Head Seg A2 Discharge Head to 36" FM Modified Curves Seg B 36"FM wye at P104 to C-FM1 See System Drawings for Corresponding Segments Seg C1 C-FM1 System Curves Seg C2 C-FM2 Seg C3 C-FM3 Suction Elevation at CS Wet Well = 43.8 13.9' Reading from Scada Seg C4 C-FM4 Discharge at Mixing Box Seg C5 C-FM5 Flows from Can-Seg PS to Mixing Box Seg D Mixing Box M-5 Segment A1 Segment A2 Segment B Segment C1 Segment C2 Segment C3 Segment C4 Segment C5 Segment D Input Flow Rate mgd 6.00 6.00 12.00 12.00 12.00 12.00 12.00 12.00 12.00 12.00 MGD Flow Rate gpm 4166.67 4166.67 8333.33 8333.33 8333.33 8333.33 8333.33 8333.33 8333.33 Flow Rate cfs 9.28 9.28 18.56 18.56 18.56 18.56 18.56 18.56 18.56 Pipe Diameter inches 20.00 20.00 36.00 36.00 36.00 36.00 36.00 36.00 36.00 Pipe Area ft^2 2.18 2.18 7.07 7.07 7.07 7.07 7.07 7.07 7.07 Hazen Williams 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 Total Pipe Length ft 8.00 68.00 880.00 1220.00 1200.00 1200.00 810.00 58.67 5444.67 Minor Losses Entrance (sharp edged) 0.50 1 Segment D Elbow, 90 0.30 2 1 1 2 Q<6.31 FALSE FALSE Elbow, 45 0.20 1 2 6.3