Attachment 7 - Preliminary Engineering Report EDA ...

Blackburn Industrial Park Grant Assistance Preliminary Engineering Report City of Gloucester, MA March 2015

report

City of Gloucester, Massachusetts March 2015 Blackburn Industrial Park Grant Assistance EDA Submittal

www.westonandsampson.com

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TABLE OF CONTENTS Page INTRODUCTION .................................................................................................................. Intro-1 TABLE OF CONTENTS ................................................................................................................. i LIST OF FIGURES ....................................................................................................................... ii LIST OF TABLES .......................................................................................................................... iii LIST OF ATTACHMENTS ........................................................................................................... iv

1.0 FLOWS AND LOADS EVALUATION ............................................................................. 1-1

2.0 INDUSTRIAL PRE-TREATMENT/LOCAL LIMITS MODIFICATION .............................. 2-1 2.1 Background ................................................................................................................ 2-1 2.2 Analysis of Proposed Industrial Wastewater Discharge ............................................. 2-2 2.3 Recommendation ....................................................................................................... 2-3 2.4 Attachments ............................................................................................................... 2-4

3.0 DOWNSTREAM SURCHARGING RELIEF ................................................................... 3-1

4.0 EVALUATION OF WASTEWATER PUMP STATIONS ................................................. 4-1 4.1 Blackburn Industrial Park Pump Station ..................................................................... 4-1 4.1.1 Background Information ............................................................................................. 4-1 4.1.2 Station Equipment ...................................................................................................... 4-1 4.1.3 Site Observations ....................................................................................................... 4-2 4.1.4 Recommendations ..................................................................................................... 4-4 4.1.5 Planning Level Cost of Improvements ........................................................................ 4-5 4.2 Heritage Way Pump Station ....................................................................................... 4-6 4.2.1 Background Information ............................................................................................. 4-6 4.2.2 Station Equipment ...................................................................................................... 4-7 4.2.3 Site Observations ....................................................................................................... 4-7 4.2.4 Recommendations ..................................................................................................... 4-9 4.2.5 Planning Level Cost of Improvements ...................................................................... 4-10

5.0 ODOR CONTROL .......................................................................................................... 5-1

6.0 SUMMARY ..................................................................................................................... 6-1

7.0 PRELIMINARY ENGINEERING REPORT REQUIREMENTS ....................................... 7-1



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LIST OF FIGURES

Figure 1 ......................................................................................................................... Locus Map Figure 2 ............................................................................................................... Topographic Map Figure 3 ........................................................................................................................ Zoning Map Figure 4 .............................................................................................................. Flood (FIRM) Map Figure 5 ........................................................................................................ Sensitive Habitat Map Figure 6 .................................................................................................... Areas of Proposed Work



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LIST OF TABLES

Table 1-1 ......................................................................... Blackburn Pump Station Tributary Flows Table 2-1 ............................... Annual Average Flows/Loads from Permitted Industrial Discharges Table 2-2 .............. Summary of Annual Flow and BOD Data from Annual Pre-Treatment Reports Table 2-3 ......................................... Annual Pre-Treatment Report Data plus Mazzetta Discharge Table 4-1 ................................................................... Blackburn Pump Station Recommendations Table 4-2 .............................................................. Heritage Way Pump Station Recommendations Table 6-1 .......................................................................................... Summary of Estimated Costs



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LIST OF ATTACHMENTS

Attachment 1 ........................................ Summary of Monthly WPCF data for Flow, BOD and TSS (from Annual Pre-Treatment reports) Attachment 2 ........................................ Summary of Monthly WPCF data for Flow, BOD and TSS Including Mazzetta BOD Load (from Annual Pre-Treatment reports) Attachment 3 ...................................................... Annual WPCP Pre-Treatment Reports Summary Including Mazzetta Flows and BOD Load



Intro-1

INTRODUCTION The City of Gloucester has worked with Mazzetta Company, LLC (Mazzetta) officials on negotiating the terms of an agreement to bring the company into the Gloucester Blackburn Industrial Park. The city will provide favorable tax increment financing for the company in order that they move into the currently vacant Good Harbors Fillet Company (Good Harbors) facility at 21 Great Republic Drive. It is anticipated that 125 full time jobs and over 100 seasonal positions will be created as a result of the Mazzetta facility being opened in Gloucester. Weston & Sampson is working with the City of Gloucester to analyze the impacts to the existing sewer collection system from the increase in wastewater flows as a result of this facility opening at the currently vacant location. The following is a Preliminary Engineering Report (PER) which is intended to supplement a federal grant application through the U.S. Department of Commerce – Economic Development Administration. The goal is that any costs resulting from required capital improvement projects within the system, as a result of this re-development project, will be offset and/or mitigated by available federal grant funds. This PER addresses the following items:

Flows and Loads Evaluation, Industrial Pretreatment and Local Limits, Downstream Surcharging Relief, Evaluation of Wastewater Pump Stations (Blackburn PS and Heritage Way PS), Odor Control, and Preliminary Engineering Report Requirements



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1.0 FLOWS AND LOADS EVALUATION In order to evaluate the impact on the City of Gloucester’s wastewater collection system of Mazzetta moving into the Blackburn Industrial Park at the site of the former Good Harbors facility, it is necessary to understand the previously existing and future load conditions of the local collection system. The “existing” and “future” flows to the collection system will then be utilized in the downstream capacity ansysis. With regard to evaluating the existing conditions, water use records from the City of Gloucester were analyzed. Future conditions were analyzed by using a February 13, 2013 letter from the Mayor of Gloucester to Mazzetta, which described the nature of wastewater flows from Mazzetta, and by evaluating the city’s GIS system to include any currently undeveloped parcels within the industrial park. A review of the GIS for the industrial park indicates that there are two potentially developable parcels within the industrial park. Those parcels are; 58 Great Republic Drive (10.76 acres) and 38 Great Republic Drive (2.53 acres). It is assumed that the parking lot at 6 Heritage Way will remain a parking area and the lot at 53 Great Republic Way, owned by the Gloucester Economic Development & Industrial Corporation (EDIC), is undevelopable based upon lot size. Based upon water use records, during the last three (3) years of operation, Good Harbors utilized approximately 28,250 gallons per day (gpd) of water. Per the February 13, 2013 letter referenced above, Mazzetta will be utilizing 150,000 gpd of water and discharging a similar volume to the wastewater collection system at a constant rate of approximately 104 gallons per minute (gpm) through the use of an equalization system. The “future” Mazzetta flows are estimated to be 121,750 gpd greater than the flows from Good Harbors, which closed in April 2012. In calculating future flows for the two undeveloped parcels, a value of 500 gpd/acre was utilized. The undeveloped parcels are assumed to potentially add approximately 6,700 gpd of flow to the collection system under a future “developed” scenario. The following is a summary of existing and future flows tributary to the Blackburn Industrial Park Pump Station. For the purposes of this analysis, water use records have not been reduced for consumption.

Table 1-1 Blackburn Pump Station Tributary Flows

EXISTING CONDITIONS FUTURE CONDITIONS

# of Parcels Average Daily

Flow (gpd) # of Parcels

Average Daily Flow (gpd)

Heritage Way PS Area(1) 6 4,425 8 11,125 Blackburn PS Area(2) 11 64,765 11 186,515 TOTAL FLOW TO BLACKBURN PS(3)

17 69,200 19 197,700

Notes: (1) Flows from the Heritage Way PS are tributary to the Blackburn PS/collection system. (2) 12 Blackburn Center has 6 buildings on one parcel. (3) Total Flows have been rounded up to the nearest 100 gpd.

Per the February 13, 2013 letter, the city has allocated 1,000 pounds per day of BOD load to the Mazzetta facility located in the Blackburn Industrial Park. The Mazzetta facility’s Industrial Pre-treatment Permit (IPP) will be closely monitored by the DPW Environmental Engineer and the IPP Coordinator.



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2.0 INDUSTRIAL PRE-TREATMENT/LOCAL LIMITS MODIFICATION

2.1 Background

As part of the normal facility operations, the Mazzetta facility has proposed a discharge of approximately 150,000 gallons per day of fish processing wastewater to the City of Gloucester sanitary sewer system. As part of the discharge, the Mazzetta facility is proposing to provide 24-hours of equalization which will result in a controlled discharge to the collection system of approximately 104 gallons per minute. The City of Gloucester Water Pollution Control Facility (WPCF) is one of the few remaining permitted primary treatment facilities in the United States. The WPCF is permitted to discharge, via a NPDES permit, for the following primary treatment parameters relevant to the proposed industrial discharge:

Average Monthly Flow – 5.15 Million Gallons per Day (MGD)

Average Monthly BOD – 245 mg/L or 10,520 lbs/day

Average Monthly TSS – 140 mg/L or 6,010 lbs/day

In 1994, the City of Gloucester updated its allowable industrial headworks loading limit for BOD at the WPCF. As part of the update, the allowable industrial headworks loading limit for BOD was increased from 1,587 lbs/day to 1,903 lbs/day. Based on the information provided in the annual pre-treatment reports, the WPCF received the following annual average flows and loads from the permitted/regulated industrial discharges:

Table 2-1 Annual Average Flows/Loads from Permitted Industrial Discharges

Year Industrial Flow (MGD) BOD Load (lbs/day)1 TSS Load (lbs/day)

2010 0.104 485 90

2011 0.112 541 106

2012 0.106 413 86

2013 0.740 303 49

Notes: 1. The industrial users are currently permitted to discharge up to 903 lbs/day of BOD leaving an unpermitted capacity of

1,000 lbs/day.

A summary of the annual average WPCF data for Flow and BOD from the annual pre-treatment reports is provided below.



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Table 2-2 Summary of Annual Flow and BOD Data from Annual Pre-Treatment Reports

Year Average Flow (MGD)

Influent BOD (lbs/day)

Effluent BOD (lbs/day)

Effluent BOD (mg/L)1

BOD Removal Percent

Capacity Remaining2

2010 4.29 12,357 6,222 174 49.69% 4,298

2011 4.33 10,520 5,027 139 52.2% 5,493

2012 3.54 8,664 4,346 147 49.8% 6,174

2013 3.49 6,463 3,587 123 44.5% 6,933

Notes: 1. The WPCF has a permitted maximum discharge concentration of 245 mg/L. 2. The WPCF has a permitted discharge allocation of 10,520 lbs/day of BOD.

It should be noted that in 2011 an upgrade in the form of enhanced chemical primary settling occurred at the WPCF.

2.2 Analysis of Proposed Industrial Wastewater Discharge

Mazzetta is proposing to discharge the following to the city of Gloucester sanitary sewer system.

Average Daily Flow – 150,000 Gallons per Day (gpd)

Average Daily BOD Allowance –1,000 lbs/day at 800 mg/L

Based on information provided by the city, the BOD of the Mazzetta discharge is anticipated to be in the soluble form. Since the BOD is anticipated to be soluble it is anticipated that it would pass through the existing primary treatment facilities. As such, we have assumed that none of the BOD from Mazzetta will be removed at the WPCF. The summary of the annual average WPCF data for Flow and BOD from the annual pre-treatment reports has been updated to include the discharge from Mazzetta. An updated version of the table is provided below. The table below is conservative, as it still includes flows and loads for Good Harbors from 2010 to 2012.

Table 2-3 Annual Pre-Treatment Report Data Plus Mazzetta Discharge

Year Flow

(MGD) BODi

(lbs/d)

Revised BODi with Mazzetta

(lbs/d)

Revised BODe (lbs/d)

Revised BODe (mg/L)

Removal Percent

Capacity Remaining1

2010 4.29 12,357 13,357 7,222 195 45.9% 3,298

2011 4.33 10,520 11,520 6,027 161 47.7% 4,493

2012 3.54 8,664 9,664 5,346 174 44.7% 5,174

2013 3.49 6,463 7,463 4,587 151 38.5% 5,933 Notes:

1. The WPCF has a permitted discharge allocation of 10,520 lbs/day of BOD. 2. BODi is the influent BOD to the WPCF. 3. Revised BODi is the influent BOD plus the 1,000 #/day from Mazzetta. 4. BODe is the effluent BOD from the WPCF.



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5. Flow information provide in this table is out of annual pretreatment reports. The revised effluent BOD calculations include an additional 150,000 gpd of flow from the Mazzetta facility.

The WPCF maximum allowable industrial headworks loading for BOD would be at the maximum allowable loading if Mazzetta is connected and allocated a BOD load of 1,000 lbs/day. However, based on the information provided in the above table, it appears that the WPCF has adequate capacity to accept the proposed industrial wastewater discharge from Mazzetta without any modifications to the WPCF. While the City of Gloucester is being proactive in bringing Mazzetta to the industrial park, the city has allocated 100% of the remaining BOD load to this one parcel. Allocating 100% of the remaining BOD load to this parcel limits the ability of Gloucester to accept/attract future industrial developments due to a lack of available Industrial Load. We would typically recommend that the city seek to maintain 10 to 20% of their available loadings for future development/re-development needs. The city should work to increase the Maximum Allowable Industrial Load (MAIL) permitted through the US EPA. In the interim, the city should continue to evaluate all IPP permits as they come up for renewal and adjust loads as appropriate to maintain a “balance” of their MAIL. Attachment #2 indicates that for several months during the low flow period the WPCF violated the concentration based limits for the effluent BOD while maintaining compliance with the load based limits for the effluent BOD. With the addition of Mazzetta, the WPCF would have also violated those same months discussed above, though no new violations would have occurred from the Mazzetta BOD load. Refer to Attachment #2 for additional information. The assumption that the entire BOD load from Mazzetta is in the soluble form is conservative. More typically, we would anticipate that 20% of the BOD from Mazzetta is in the inert or colloidal phases, and as such the WPCF would be able to remove 20% of the BOD from Mazzetta. If the WPCF were able to remove 20% of the BOD from Mazzetta, the revised effluent loads/concentrations would be less than those identified in Attachment #2. It should be noted that only monthly average data for flows and pollutant loads (BOD & TSS) was provided within the annual pre-treatment reports. A more thorough analysis should be completed utilizing the daily operating data from the date that the recent WPCF upgrade was completed. This information could then be utilized for an update to the Maximum Allowable Industrial Loadings to the WPCF.

2.3 Recommendation

Based on a review of the WPCF information provided in the 2010 through 2013 annual pre-treatment reports the WPCF has adequate BOD capacity remaining for the connection of Mazzetta. The City may therefore proceed with the connection of Mazzetta. It is unclear if Mazzetta will be required to construct/operate an onsite pre-treatment system. At a minimum, the City should require Mazzetta to reserve space for a future pre-treatment system should it be required in the future due to changes in the city’s NPDES permit requirements/status. As part of the connection of Mazzetta, the city should conduct a headwork’s loading analysis of the WPCF. The headwork’s loading analysis can then be utilized as justification for a revision to the Maximum Allowable Industrial Loadings for both BOD and TSS under the EPA Pre-Treatment Program. A review of the data indicates that the City has a substantial amount of BOD and TSS capacity remaining at the WPCF. An engineering budget of $60,000 should be allocated towards re-evaluating the existing City of Gloucester local limits and working with US



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EPA to increase the maximum allowable industrial load (MAIL) for the city. The city will separately budget this work item, and it is NOT included for consideration in this grant application. As discussed later in this report, a substantial amount of grease/sludge/solids has been observed in the Heritage Way PS wetwell, the Blackburn PS wetwell and the downstream collection system. This observation during our field visit is consistent with prior observations by the City of Gloucester. The city has identified the likely culprit of the grease/sludge/solids as the facility located at 12 Heritage Way (Custom Seasonings, Inc.). The city has indicated that they are working with this business on eliminating the discharge of the grease/sludge/solids to the collection system, but they have not achieved success at this point. A review of the 2013 Industrial Pretreatment Program Report indicates that the Custom Seasonings facility is not currently permitted under the Industrial Pretreatment Program. Based upon our observations, and the lack of success Gloucester has had working with Custom Seasonings on eliminating the discharge of grease/sludge/solids to the collection system, Gloucester may want to include Custom Seasonings in the IPP Program and consider appropriate actions should they continue to discharge grease/sludge/solids to the collection system. At a minimum, the city should consider having Custom Seasonings pay for the investigations, flushing/cleaning and force main pigging recommended under the PS Improvements section of this report.

2.4 Attachments

Attachments used in the analysis of the future loadings of the Mazzetta facility on the WPCF are included at the end of this section. The attachments provide the following information:

1. Attachment #1 - Summary of the monthly WPCF data for Flow, BOD and TSS from the annual pre-treatment reports.

2. Attachment #2 - Summary of the monthly WPCF data for Flow, BOD and TSS from the annual pre-treatment reports updated to include the BOD load from Mazzetta assuming a complete pass through of the BOD load from Mazzetta.

3. Attachment #3 –Annual WPCF Pre-Treatment Reports Summary with Mazzetta Company LLC facility flows and BOD Loads added.

It should be noted that there is a discrepancy between the load and concentration data provided within the annual pre-treatment reports. As such we have utilized the concentration data which has resulted in a slight increase in the loads, and appears to be a more conservative assumption.



ATTACHMENTS

Flow BOD Removal TSS Removal Effluent Oil &

Grease Total Petroleum Hydrocarbons

12 Month Flow Rolling Average

Month MGD mg/L lbs/Day mg/L lbs/Day % mg/L lbs/Day mg/L lbs/Day % mg/L mg/L MGD

Jan-10 4.61 200 7,689 142 5,460 29.0% 150 5,767 84 3,230 44.0% 3,387.0 15.40 1.50

Feb-10 4.20 253 8,862 137 4,799 45.8% 167 5,850 77 2,697 53.9% 2,731.0 21.00 1.20

Mar-10 8.30 122 8,445 74 5,122 39.3% 108 7,476 61 4,223 43.5% 4,390.0 15.80 1.40

Apr-10 5.02 227 9,504 128 5,359 43.6% 147 6,154 57 2,386 61.2% 2,235.0 8.50 2.60

May-10 3.59 257 7,695 139 4,162 45.9% 217 6,497 82 2,455 62.2% 2,588.0 16.20 1.40

Jun-10 3.78 291 9,174 160 5,044 45.0% 318 10,025 94 2,963 70.4% 2,924.0 10.60 0.90

Jul-10 3.51 563 16,481 277 8,109 50.8% 497 14,549 100 2,927 79.9% 2,815.0 14.40 4.00

Aug-10 3.66 518 15,812 258 7,875 50.2% 370 11,294 98 2,991 73.5% 3,371.0 17.40 2.60

Sep-10 3.39 704 19,904 268 7,577 61.9% 447 12,638 89 2,516 80.1% 2,466.0 9.60 1.00

Oct-10 3.70 588 18,145 284 8,764 51.7% 521 16,077 93 2,870 82.1% 3,041.0 10.10 1.00

Nov-10 4.10 438 14,977 222 7,591 49.3% 301 10,292 83 2,838 72.4% 2,942.0 13.40 2.00

Dec-10 3.62 384 11,593 159 4,800 58.6% 355 10,718 72 2,174 79.7% 2,107.0 10.50 5.00

Jan-11 4.41 371 13,645 156 5,738 58.0% 266 9,783 75 2,758 71.8% 12.1 2.00 4.25

Feb-11 5.07 291 12,305 158 6,681 45.7% 254 10,740 67 2,833 73.6% 12.1 2.20 4.32

Mar-11 4.96 224 9,266 120 4,964 46.4% 223 9,225 66 2,730 70.4% 9.2 3.00 4.07

Apr-11 4.86 230 9,322 113 4,580 50.9% 252 10,214 66 2,675 73.8% 8.3 4.00 4.05

May-11 3.63 283 8,568 139 4,208 50.9% 348 10,535 69 2,089 80.2% 9.6 2.00 4.06

Jun-11 3.70 359 11,078 163 5,030 54.6% 363 11,201 86 2,654 76.3% 8.8 0.00 4.05

Jul-11 3.93 323 10,587 171 5,605 47.1% 355 11,636 69 2,262 80.6% 9.8 0.00 4.09

Aug-11 4.60 304 11,663 137 5,256 54.9% 295 11,317 71 2,724 75.9% 9.0 0.00 4.16

Sep-11 3.78 357 11,254 134 4,224 62.5% 341 10,750 58 1,828 83.0% 10.3 0.00 4.20

Oct-11 4.60 246 9,438 124 4,757 49.6% 230 8,824 48 1,841 79.1% 9.5 3.00 4.27

Nov-11 4.25 263 9,322 136 4,821 48.3% 203 7,195 58 2,056 71.4% 10.0 2.00 4.28

Dec-11 4.15 283 9,795 129 4,465 54.4% 239 8,272 47 1,627 80.3% 14.0 3.00 4.33

Jan-12 3.71 309 9,561 152 4,703 50.8% 304 9,406 55 1,702 81.9% 12.4 5.00 4.27

Feb-12 3.33 433 12,025 145 4,027 66.5% 484 13,442 61 1,694 87.4% 22.8 2.00 4.13

Mar-12 3.51 303 8,870 145 4,245 52.1% 310 9,075 58 1,698 81.3% 12.5 4.00 4.00

Apr-12 3.32 268 7,421 133 3,683 50.4% 310 8,584 57 1,578 81.6% 9.5 4.00 3.88

May-12 3.89 253 8,208 122 3,958 51.8% 309 10,025 50 1,622 83.8% 8.6 1.00 3.90

Jun-12 4.07 255 8,656 131 4,447 48.6% 330 11,201 69 2,342 79.1% 8.3 1.00 3.93

Attachment #1 - 2010 through 2013 WPCF Annual Pre-Treatment Reports Data Summary

Effluent Total Suspended Solids

Influent BOD Effluent BOD Daily Influent Total Suspended

Solids

Flow BOD Removal TSS Removal Effluent Oil &

Grease Total Petroleum Hydrocarbons

12 Month Flow Rolling Average

Month MGD mg/L lbs/Day mg/L lbs/Day % mg/L lbs/Day mg/L lbs/Day % mg/L mg/L MGD

Attachment #1 - 2010 through 2013 WPCF Annual Pre-Treatment Reports Data Summary

Effluent Total Suspended Solids

Influent BOD Effluent BOD Daily Influent Total Suspended

Solids

Jul-12 3.49 345 10,042 167 4,861 51.6% 320 9,314 47 1,368 85.3% 8.2 2.00 3.89

Aug-12 3.35 329 9,192 173 4,833 47.4% 315 8,801 55 1,537 82.5% 9.0 3.00 3.79

Sep-12 3.30 269 7,403 169 4,651 37.2% 245 6,743 50 1,376 79.6% 10.3 3.00 3.75

Oct-12 3.19 278 7,396 156 4,150 43.9% 207 5,507 67 1,783 67.6% 11.2 5.00 3.63

Nov-12 3.12 287 7,468 151 3,929 47.4% 230 5,985 59 1,535 74.3% 11.5 2.00 3.54

Dec-12 4.17 222 7,721 134 4,660 39.6% 176 6,121 54 1,878 69.3% 10.5 2.00 3.54

Jan-13 3.43 224 6,408 126 3,604 43.8% 175 5,006 51 1,459 70.9% 7.2 4.00 3.51

Feb-13 4.11 180 6,170 113 3,873 37.2% 161 5,519 50 1,714 68.9% 10.8 4.00 3.58

Mar-13 5.00 121 5,046 76 3,169 37.2% 127 5,296 41 1,710 67.7% 8.3 2.00 3.70

Apr-13 3.11 277 7,185 109 2,827 60.6% 251 6,510 47 1,219 81.3% 8.0 2.00 3.69

May-13 3.11 276 7,159 137 3,553 50.4% 334 8,663 50 1,297 85.0% 14.8 3.90 3.62

Jun-13 5.04 188 7,902 102 4,287 45.7% 259 10,887 58 2,438 77.6% 8.5 5.00 3.70

Jul-13 3.57 240 7,146 138 4,109 42.5% 239 7,116 50 1,489 79.1% 6.2 3.00 3.71

Aug-13 3.03 289 7,303 154 3,892 46.7% 318 8,036 63 1,592 80.2% 11.3 4.00 3.68

Sep-13 2.68 310 6,929 155 3,464 50.0% 345 7,711 54 1,207 84.3% 11.5 4.00 3.63

Oct-13 2.74 235 5,370 152 3,473 35.3% 245 5,599 52 1,188 78.8% 15.0 4.80 3.59

Nov-13 2.72 248 5,626 158 3,584 36.3% 248 5,626 69 1,565 72.2% 15.8 5.00 3.56

Dec-13 3.32 192 5,316 116 3,212 39.6% 215 5,953 71 1,966 67.0% 9.2 3.00 3.49

Minimum 2.68 121 5,046 74 2,827 29.0% 108 5,006 41 1,188 43.5% 6.2 0.00 0.90

Maximum 8.30 704 19,904 284 8,764 66.5% 521 16,077 100 4,223 87.4% 4,390.0 21.00 5.00

Average 3.91 291 9,501 147 4,796 49.5% 270 8,816 65 2,111 74.7% 737.1 5.48 3.43

Yearly Average

2010 4.29 345 12,357 174 6,222 49.6% 273 9,778 80 2,856 70.8% 2,916.42 13.58 2.05

2011 4.33 291 10,520 139 5,027 52.2% 276 9,974 65 2,340 76.5% 10.23 1.77 4.18

2012 3.54 294 8,664 147 4,346 49.8% 294 8,684 57 1,676 80.7% 11.23 2.83 3.85

2013 3.49 222 6,463 123 3,587 44.5% 235 6,827 54 1,570 77.0% 10.55 3.73 3.62

Flow BOD Removal WPCF NPDES

Capacity

Month MGD WPCF mg/L WPCF lbs/d Industry lbs/dRevised Total

lbs/dRevised Total

mg/LWPCF mg/L WPCF lbs/d Industry lbs/d

Revised Total lbs/d

Revised mg/L % lbs/d lbs/d %

Jan-10 4.61 200 7,689 1,000 8,689 219 142 5,460 1,000 6,460 163 25.7% 10,520 4,060 38.6%

Feb-10 4.20 253 8,862 1,000 9,862 272 137 4,799 1,000 5,799 160 41.2% 10,520 4,721 44.9%

Mar-10 8.30 122 8,445 1,000 9,445 134 74 5,122 1,000 6,122 87 35.2% 10,520 4,398 41.8%

Apr-10 5.02 227 9,504 1,000 10,504 244 128 5,359 1,000 6,359 147 39.5% 10,520 4,161 39.6%

May-10 3.59 257 7,695 1,000 8,695 279 139 4,162 1,000 5,162 165 40.6% 10,520 5,358 50.9%

Jun-10 3.78 291 9,174 1,000 10,174 310 160 5,044 1,000 6,044 184 40.6% 10,520 4,476 42.5%

Jul-10 3.51 563 16,481 1,000 17,481 573 277 8,109 1,000 9,109 298 47.9% 10,520 1,411 13.4%

Aug-10 3.66 518 15,812 1,000 16,812 529 258 7,875 1,000 8,875 279 47.2% 10,520 1,645 15.6%

Sep-10 3.39 704 19,904 1,000 20,904 708 268 7,577 1,000 8,577 291 59.0% 10,520 1,943 18.5%

Oct-10 3.70 588 18,145 1,000 19,145 596 284 8,764 1,000 9,764 304 49.0% 10,520 756 7.2%

Nov-10 4.10 438 14,977 1,000 15,977 451 222 7,591 1,000 8,591 242 46.2% 10,520 1,929 18.3%

Dec-10 3.62 384 11,593 1,000 12,593 401 159 4,800 1,000 5,800 184 53.9% 10,520 4,720 44.9%

Jan-11 4.41 371 13,645 1,000 14,645 385 156 5,738 1,000 6,738 177 54.0% 10,520 3,782 36.0%

Feb-11 5.07 291 12,305 1,000 13,305 306 158 6,681 1,000 7,681 176 42.3% 10,520 2,839 27.0%

Mar-11 4.96 224 9,266 1,000 10,266 241 120 4,964 1,000 5,964 140 41.9% 10,520 4,556 43.3%

Apr-11 4.86 230 9,322 1,000 10,322 247 113 4,580 1,000 5,580 134 45.9% 10,520 4,940 47.0%

May-11 3.63 283 8,568 1,000 9,568 303 139 4,208 1,000 5,208 165 45.6% 10,520 5,312 50.5%

Jun-11 3.70 359 11,078 1,000 12,078 376 163 5,030 1,000 6,030 188 50.1% 10,520 4,490 42.7%

Jul-11 3.93 323 10,587 1,000 11,587 341 171 5,605 1,000 6,605 194 43.0% 10,520 3,915 37.2%

Aug-11 4.60 304 11,663 1,000 12,663 320 137 5,256 1,000 6,256 158 50.6% 10,520 4,264 40.5%

Sep-11 3.78 357 11,254 1,000 12,254 374 134 4,224 1,000 5,224 159 57.4% 10,520 5,296 50.3%

Oct-11 4.60 246 9,438 1,000 10,438 263 124 4,757 1,000 5,757 145 44.8% 10,520 4,763 45.3%

Nov-11 4.25 263 9,322 1,000 10,322 281 136 4,821 1,000 5,821 159 43.6% 10,520 4,699 44.7%

Dec-11 4.15 283 9,795 1,000 10,795 301 129 4,465 1,000 5,465 152 49.4% 10,520 5,055 48.1%

Jan-12 3.71 309 9,561 1,000 10,561 328 152 4,703 1,000 5,703 177 46.0% 10,520 4,817 45.8%

Feb-12 3.33 433 12,025 1,000 13,025 449 145 4,027 1,000 5,027 173 61.4% 10,520 5,493 52.2%

Mar-12 3.51 303 8,870 1,000 9,870 323 145 4,245 1,000 5,245 172 46.9% 10,520 5,275 50.1%

Apr-12 3.32 268 7,421 1,000 8,421 291 133 3,683 1,000 4,683 162 44.4% 10,520 5,837 55.5%

May-12 3.89 253 8,208 1,000 9,208 273 122 3,958 1,000 4,958 147 46.2% 10,520 5,562 52.9%

Jun-12 4.07 255 8,656 1,000 9,656 274 131 4,447 1,000 5,447 155 43.6% 10,520 5,073 48.2%

Attachment #2 - 2010 through 2013 WPCF Annual Pre-Treatment Reports Data Summary with Mazzetta Company LLC facility Flows and BOD Loads Added

Remaining NPDES Capacity

Effluent BOD - lbs/day Influent BOD

Flow BOD Removal WPCF NPDES

Capacity

Month MGD WPCF mg/L WPCF lbs/d Industry lbs/dRevised Total

lbs/dRevised Total

mg/LWPCF mg/L WPCF lbs/d Industry lbs/d

Revised Total lbs/d

Revised mg/L % lbs/d lbs/d %

Attachment #2 - 2010 through 2013 WPCF Annual Pre-Treatment Reports Data Summary with Mazzetta Company LLC facility Flows and BOD Loads Added


Effluent BOD - lbs/day Influent BOD

Jul-12 3.49 345 10,042 1,000 11,042 364 167 4,861 1,000 5,861 193 46.9% 10,520 4,659 44.3%

Aug-12 3.35 329 9,192 1,000 10,192 349 173 4,833 1,000 5,833 200 42.8% 10,520 4,687 44.5%

Sep-12 3.30 269 7,403 1,000 8,403 292 169 4,651 1,000 5,651 196 32.8% 10,520 4,869 46.3%

Oct-12 3.19 278 7,396 1,000 8,396 301 156 4,150 1,000 5,150 185 38.7% 10,520 5,370 51.0%

Nov-12 3.12 287 7,468 1,000 8,468 311 151 3,929 1,000 4,929 181 41.8% 10,520 5,591 53.1%

Dec-12 4.17 222 7,721 1,000 8,721 242 134 4,660 1,000 5,660 157 35.1% 10,520 4,860 46.2%

Jan-13 3.43 224 6,408 1,000 7,408 248 126 3,604 1,000 4,604 154 37.8% 10,520 5,916 56.2%

Feb-13 4.11 180 6,170 1,000 7,170 202 113 3,873 1,000 4,873 137 32.0% 10,520 5,647 53.7%

Mar-13 5.00 121 5,046 1,000 6,046 141 76 3,169 1,000 4,169 97 31.0% 10,520 6,351 60.4%

Apr-13 3.11 277 7,185 1,000 8,185 301 109 2,827 1,000 3,827 141 53.2% 10,520 6,693 63.6%

May-13 3.11 276 7,159 1,000 8,159 300 137 3,553 1,000 4,553 167 44.2% 10,520 5,967 56.7%

Jun-13 5.04 188 7,902 1,000 8,902 206 102 4,287 1,000 5,287 122 40.6% 10,520 5,233 49.7%

Jul-13 3.57 240 7,146 1,000 8,146 263 138 4,109 1,000 5,109 165 37.3% 10,520 5,411 51.4%

Aug-13 3.03 289 7,303 1,000 8,303 313 154 3,892 1,000 4,892 184 41.1% 10,520 5,628 53.5%

Sep-13 2.68 310 6,929 1,000 7,929 336 155 3,464 1,000 4,464 189 43.7% 10,520 6,056 57.6%

Oct-13 2.74 235 5,370 1,000 6,370 264 152 3,473 1,000 4,473 186 29.8% 10,520 6,047 57.5%

Nov-13 2.72 248 5,626 1,000 6,626 277 158 3,584 1,000 4,584 192 30.8% 10,520 5,936 56.4%

Dec-13 3.32 192 5,316 1,000 6,316 218 116 3,212 1,000 4,212 146 33.3% 10,520 6,308 60.0%

Minimum 2.68 121 5,046 1,000 6,046 134 74 2,827 1,000 3,827 87 25.7% 10,520 756 7.2%

Maximum 8.30 704 19,904 1,000 20,904 708 284 8,764 1,000 9,764 304 61.4% 10,520 6,693 63.6%

Average 3.91 291 9,501 1,000 10,501 322 147 4,796 1,000 5,796 178 44.8% 10,520 4,724 44.9%

Yearly Average

2010 4.29 345 12,357 1,000 13,357 361 174 6,222 1,000 7,222 195 45.9% 10,520 3,298 31.4%

2011 4.33 291 10,520 1,000 11,520 308 139 5,027 1,000 6,027 161 47.7% 10,520 4,493 42.7%

2012 3.54 294 8,664 1,000 9,664 314 147 4,346 1,000 5,346 174 44.7% 10,520 5,174 49.2%

2013 3.49 222 6,463 1,000 7,463 246 123 3,587 1,000 4,587 151 38.5% 10,520 5,933 56.4%Note: Revised BOD Concentrations include an additional 150,000 gpd for the additional industrial flow. See attachment 3 for additional information/clarity.

Original Revised w/ Mazzatta Original Original Revised w/ Mazzatta Revised w/ Mazzatta Original Original Revised w/ Mazzatta Revised w/ Mazzatta

MGD MGD WPCF mg/L WPCF lbs/d WPCF mg/L WPCF lbs/d WPCF mg/L WPCF lbs/d WPCF mg/L WPCF lbs/d % lbs/d lbs/d %

2010 4.29 4.44 345 12,357 361 13,357 174 6,222 195 7,222 45.9% 10,520 3,298 31.4%

2011 4.33 4.48 291 10,520 308 11,520 139 5,027 161 6,027 47.7% 10,520 4,493 42.7%

2012 3.54 3.69 294 8,664 314 9,664 147 4,346 174 5,346 44.7% 10,520 5,174 49.2%

2013 3.49 3.64 222 6,463 246 7,463 123 3,587 151 4,587 38.5% 10,520 5,933 56.4%


Attachment #3 - WPCF Annual Pre-Treatment Reports Revised Annual Data Summary with Mazzetta Company LLC facility Flows and BOD Loads Added

Influent BOD Effluent BOD - lbs/day Flow

Year

BOD Removal

WPCF NPDES

Capacity



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3.0 DOWNSTREAM SURCHARGING RELIEF The City of Gloucester DPW staff has indicated that a surcharging condition exists in the Harrison Avenue sewer system whenever the Blackburn Industrial Park PS discharges flow. The original Harrison Avenue sewer was installed in 1941 and extended sewer service to a location just north of the intersection of Harrison Avenue and Skywood Terrace. In the early 1970’s the Blackburn Industrial Park PS was installed and the gravity sewer on Harrison Avenue was extended by approximately 850 feet. The Blackburn Industrial Park PS force main discharges into the gravity sewer extension.

Field investigations by city staff have observed surcharging in three manholes in Harrison Avenue. The surcharging manholes are located at the intersection of Harrison Avenue and Skywood Terrace and the manholes just north and south of the aforementioned intersection. Our model run for the sewer system also showed surcharging (approximately 3.5 inches) in the aforementioned manholes when the Blackburn Industrial Park PS discharges flow. The surcharging condition in the area of Skywood Terrace is the result of this being the flattest section of sewer in the Harrison Avenue gravity sewer system. Upstream and downstream sections of the sewer have slopes of between 5.5% and 10%, while the surcharged section of the system has a slope of approximately 0.6%. As the sewer enters the flatter sections of the line, the velocity is greatly reduced, which results in the surcharging condition.

In order to alleviate the surcharging condition, the forcemain discharge from the Blackburn Industrial Park PS can be extended approximately 2,700 linear feet from the current location to the manhole at the intersection of Eastern Avenue and Neptune Place. Bypassing the flat sections of the collection system and discharging to a larger diameter gravity pipe (12-inch) at Eastern Ave/Neptune Place will reduce the surcharging conditions which could potentially result in sanitary sewer backups in buildings connected to the surcharged sewer system. The increase in flows from the Mazzetta project will moderately exacerbate the existing surcharging issue, which may increase the potential for sewer backups if not addressed.

The installation of approximately 2,700 lf of 6-inch ductile iron forcemain (including 35% engineering/contingency) would cost the city approximately $456,000. This assumes a value of $125 per linear foot (assumed to include 20% contractor OH&P) is appropriate for the purchase and installation of the forcemain and trench pavement restoration. Geotechnical investigations are recommended to determine if ledge or other unsuitable materials will be encountered during the installation work.

As part of our Preliminary Engineering Report efforts, Weston & Sampson found that the Downstream Collection System has existing capacity issues which are exacerbated by the increase in flow from the Mazzetta Project. As a separate project, we recommend that the City work to remove Infiltration and Inflow from the Downstream Collection System. A budget for this work has NOT been included in this Grant Application Package.



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4.0 EVALUATION OF WASTEWATER PUMP STATIONS

4.1 Blackburn Industrial Park Pump Station

4.1.1 Background Information

The Blackburn Industrial Park PS (Blackburn PS) is located at the intersection of Blackburn Drive and Great Republic within the Blackburn Industrial Park. Records from the pump station indicate that the pump station was constructed in the early 1970’s. The Blackburn PS is a below grade, ‘dry-pit’ type pump station. The station consists of an 8-foot diameter precast concrete vault structure with a 3.5-foot diameter precast concrete access tube. The station was once accessed via an entrance hatch located on top of the entrance tube, though it has been replaced with a fabricated wooden cover with no provisions for locking. The station’s pump chamber is accessed via a painted steel ladder. The floor of the station is approximately 18-feet below grade. The existing wetwell is constructed of pre-cast concrete manhole sections topped with a manhole cone and a 24-inch sewer manhole cover. It is assumed that the interior diameter of wetwell structure within the operating range is 8-feet in diameter, though this could not be verified due to access limitations. The wetwell also has embedded aluminum steps for access. The wet well includes a bubbler tube system for level control and pump operation. A backup high level float was not observed. The pumping system consists of two vertical centrifugal solids handling pumps that are housed in the concrete can structure. Each of the pumps draw flow from the adjacent 8-foot (assumed inside diameter) pre-cast concrete wet well through 6-inch suction lines. The 6-inch discharge lines from each pump are then joined together into one 6-inch diameter force main, which exits the dry pit structure through the wall. The pump station force main, which is 6-inch diameter cement lined cast iron pipe (per available record drawings), generally runs in a northeast direction through an easement in the industrial park before turning and discharging to a gravity sewer manhole on Harrison Avenue approximately 725 feet from the Blackburn PS. It should also be noted that the Heritage Way Pump Station, which is also located in the industrial park, discharges to the gravity collection system which is connected to the Blackburn PS. The Blackburn PS operates on a fill/draw cycle controlled by a bubbler tube level control system. At the time of our visit, the pumps were set to operate at a liquid elevation of 58-inches (above wetwell floor) and turn off at an elevation of 35-inches. Low water alarm is set at 16-inches and the high water alarm elevation is set at 82-inches. The lag pump was set to turn on at 69-inches and turn off at 45-inches. At the time of our visit on July 10, 2014, there was not enough flow to conduct a drawdown test, so current pump outputs could not be verified. The pump station does not have a dedicated generator set for stand-by power. A receptacle for connection of a portable generator for use during extended power outages is available. The city has a portable generator that can be used at the site.

4.1.2 Station Equipment Station Manufacturer: Liftmaster, Inc. Number of Pumps: 2

Pump Manufacturer: Fairbanks Morse Motor Manufacturer: General Electric



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Model Number: 5443B62 Model: 5K6236XH206B

Serial Number: KTAP101206 & TAP101208-1

Serial Number: 5903493911

Size: 4x6-inch Horsepower: 10 Rated Capacity: 400 gpm @ 48’ TDH Speed: 1150 RPM Seals: Mechanical Seal Service Factor: 1.15 Impeller Size: 12-inches Rating: 3 ph./208volts/60hz Run Time (hrs): 1397.9 (P1)

7873.1 (P2) 252.8 (Both)

Frame: 256TP12

Actuating Controls: Bubbler System (Dual compressors – Gast 1/6 HP Compressors) Operating Controls: Omnitrol – Model 2199B1002 Stand-by Generator Manufacturer:

PORTABLE GENERATOR RECEPTACLE

Sump Pump Manufacturer:

Zoeller

Model: Rated Capacity: No Tag Visible Serial Number: Size: Heater: Chromalox

(Unit is non-funtional) Engine: Dehumidifier: Danby Run Time (hrs): Fuel: Fuel Tank Size: Data Sources:

1 Information taken from equipment tag or nameplate during 2014 site visits. 2 Information taken from 2012 evaluation by W&S CMR Division. 3 Operation & Maintenance Manual information provided by Gloucester.

4.1.3 Site Observations

During our site visit, visual inspection was conducted for station exterior, electrical panels, breakers, control panels, and wetwell walls and interior (topside inspection only). Also performed was miscellaneous inspection of pumps and motors, check and gate valves and mechanical piping. Based upon pump run time observations from our July 10, 2014 visit and the April 5, 2012 evaluation by Weston & Sampson CMR, it appears that the pumps in this station have been operating approximately 1.5 hours per day. At the rated capacity of the pumps (400 gpm), this equates to approximately 36,000 gallons per day of wastewater through the pump station. We made the following general observations and identified the following deficiencies about the Blackburn PS.

General Mechanical

• A significant amount of solids/grease/sludge was observed to be accumulating in the sewer manhole upstream of the wetwell.

• The station operator indicated that the wetwell has not been cleaned in quite some time.

• The wetwell structure is accessed through a manhole frame and cover.



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• The operator indicated that the city does not have a supply of spare parts on-hand for this station.

• Pump #2 was “offline” due to a failed seal. • Flows were not significant enough at the time of our visit to conduct a wetwell

drawdown test. • The valves are old and need to be replaced. • The entry tube for the station is missing a hatch and is covered with a homemade

wooden cover, which does not have a lock. • The pump chamber has a powered exhaust fan and a gravity intake. • The heater for the pump chamber was non-functional. • A residential type dehumidification unit was in the pump chamber. • The pump chamber has a single sump pump, which appeared functional yet

dated. • The station appears to have a bypass connection located in a sewer manhole

outside of the fenced in pump station site. • The site is completely enclosed with a chainlink fence. • The pumps appear to be original equipment from the 1971 install and have

surpassed their useful life. • Pump removal for maintenance operations appears to be difficult due to limited

clearance between pump motor and underside of ceiling in can structure.

Electrical, Controls, Alarms

• The portable engine/generator receptacle wiring must be checked to verify it properly “grounds” the portable engine/generator.

• The below grade pump station has a personnel emergency assistance button, but does not have a sump pump flood alarm, combustible gas alarm, smoke detector alarm, etc., which would provide improved operator safety and increased pump station operation reliability.

• The incoming power does not have surge protection (TVSS) device electrical protection equipment. The existing utility power is 240 volts, 3 phase wire (ungrounded). Note, if one of the phase wires fails to ground the remaining two phases will have over-voltage conditions, which can fail the electrical equipment and sewage pump motors.

• The wetwell level sensing consists of a bubbler line with two (2) air compressors. Note, this technology is old and maintenance intensive. Also, the pump controls consist of bubbler air pressure switches and old style control relays pump control logic.

• The pump station is missing alarms (intrusion, etc.), plus the alarms should be segregated into “critical process”, “non-critical process”, “intrusion” and “emergency” zones to enable the operator to properly respond. The radio telemetry system is limited, and it is manufactured by a relatively unknown supplier which could hinder parts procurement and service.

• Missing multi-phase electrical power supply relay and its power failure alarm. In addition, due to the “ungrounded” electrical service, an over-voltage ground fault



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relay is required, which would automatically de-energize the utility electrical service to protect the pump station equipment.

• The below grade pump station lighting consists of incandescent type lights without any type of emergency battery back-up lighting which makes the egress from the station via the access ladder hazardous. New screw in LED type lamps should be installed.

• No exterior mounted GFI type exterior receptacle is located at the outdoor equipment for maintenance purposes (i.e. wetwell cleaning, etc.).

Structural

• The concrete tube for the pump station appears to be in good condition. • A small crack was observed on the ceiling of the structure adjacent to a lifting

hook for the pumps.

Safety Considerations

• The station has an old style safe entry device for accessing the tube, but this should be replaced with a safer and more reliable ladder up type device.

• The wetwell has embedded aluminum ladder rungs and a separate ladder device in the lower portion of the structure. One of the rungs on the lower ladder has completely corroded.

4.1.4 Recommendations

Based on the evaluation, we recommend that the following items be addressed to improve the reliability and safety of the pump station. Recommendations have been prioritized into short term (1 to 3 year) and long term (greater than 3 year) recommendations Short Term Recommendations

General Mechanical

• Clean upstream sewer line to remove accumulated solids, sludge and grease. • Evaluate the condition of the forcemain for the station, as clogging may be

occurring. It should be assumed that the force main requires cleaning or “pigging”. • Clean wetwell to remove accumulated solids, sludge and grease. • The pump station has reached the end of its useful life and since maintenance

activities are difficult due to the existing configuration, consideration should be given to replacing the pump station in its entirety. The existing station should be demolished and replaced with a new submersible pump station with above grade controls. The work includes a new wetwell structure, new valve vault, new above grade SCADA capable controls and a new standby generator. (Note, the current operator does not like submersible pump stations, but they are reliable and cost effective solutions. Additional monies should be carried should an alternate pump station design be considered.)


• Included in complete PS replacement with new submersible pump station.



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Structural




Long Term Recommendations

General Mechanical

• No Recommendations Identified.


• No Recommendations Identified. Structural




4.1.5 Planning Level Cost of Improvements

Table 4-1 Blackburn Pump Station Recommendations

Description of Recommendation Estimated

Cost Blackburn PS - Short Term (1-3 years) General Mechanical u Clean the upstream sewer line to remove accumulated solids, sludge and

grease. $5,000

u Evaluate the condition of the forcemain for the station as clogging may be occurring. It should be assumed that the force main requires "pigging".

$7,500

u

Replace the existing pump station with a new subersible type pump station. Work includes demolition of old station, new wetwell structure, new valve vault, new above grade SCADA capable controls and a new standby generator

$330,000

Short-Term Needs Subtotal $343,000

Pump Station Subtotal $343,000

General Contractor Overhead & Mark-up (20%) $69,000

Engineering & Contingency (35%) $121,000

Pump Station Total $533,000



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4.2 Heritage Way Pump Station

4.2.1 Background Information

The Heritage Way PS is located off of the Heritage Way cul-de-sac in the Blackburn Industrial Park. The station was constructed in 1996 as part of the Blackburn Industrial Park expansion project. The Heritage Way PS is a newer submersible type sewer pump station utilizing duplex submersible grinder pumps. The station wetwell is 5-foot in diameter and is constructed of pre-cast concrete sections with an access hatch cast in the top slab, which is approximately 6-inches above finished grade. The discharge valving is installed in an external valve vault in order to limit the need to enter the wetwell space. The station is equipped with a dedicated standby generator to provide power to the station in the event of a service power failure. Controls for the pump station, the automatic transfer switch for the generator, the alarm auto-dialer and the electrical panels/transformer are located in an above grade outdoor weatherproof enclosure. The pump station site is completely fenced in and accessed via a crushed stone driveway. The area within the barbed-wired topped fence is not finished with crushed stone. The pumping system consists of two submersible grinder pumps that are mounted in the wetwell. Each of the pumps draws flow from the 5-foot (inside diameter) pre-cast concrete wet well and discharge flow through 3-inch ductile iron discharge lines. The 3-inch discharge lines from each pump then exit the wetwell through the wall and enter the valve vault. Inside the valve vault each line is provided with a 3-inch check valve and 3-inch gate valve prior to joining together at a 3x3x3 tee. A second 3x3x3 tee is provided, which allows piped bypass connection of the station, before the 3-inch force main exits the valve vault. The bypass connection consists of a 3-inch gate valve and 3-inch threaded nipple, adaptor and cap. After the piping exits the valve vault it converts to 3-inch PVC. The pump station 3-inch diameter force main runs approximately 400-feet south through a utility easement before entering Great Republic Drive and travelling west approximately 750-feet prior to discharging to a gravity sewer manhole opposite 21 Great Republic Drive. The total forcemain length from the pump station to discharge location is approximately 1,150 linear feet. The Heritage Way PS operates on a fill/draw cycle controlled by a simplex bubbler tube/compressor system. The pump station controls provide automatic alternation of the lead pump after each pumping cycle when under bubbler tube system control. In the event of a bubbler tube system failure, the station is equipped with a back-up high level float. At the time of our visit, the following level settings (above wetwell floor) were observed: • Pump On (lead) – 64-inches • Pump On (lag) – 70-inches • Pumps Off – 44-inches • High Level Alarm – 75-inches • Hi Level Float – 81-inches • Low level alarm – 36-inches In addition to monitoring high and low level conditions in the wetwell, the pump station controls monitor; loss of power, pump overload, pump over temperature, pump seal leak and compressor failure. Alarm notifications are delivered to the city via an autodialer system. The pump station has a dedicated standby generator to provide power to the station in the event of a power failure. Due to multiple active yellow jacket nests observed inside the generator set during the time of our visit, a detailed analysis of the generator was not able to be performed.



4-7

Discussions with city staff have indicated that the existing generator at the site is non-functional and needs replacement. The city has procured a replacement generator and is working to have the new generator installed at the site.

4.2.2 Station Equipment Station Manufacturer: Number of Pumps: 2

Pump Manufacturer: Hydromatic Motor Manufacturer: Hydromatic Model Number: SPGH/G2HX500 Model: SPGH/G2HX500 Serial Number: Unknown Serial Number: Unknown Size: Unknown Horsepower: 5 HP

Rated Capacity: 80 gpm @ 80 feet Speed: Unknown Seals: Double Mechanical Service Factor: Impeller Size: 6.75 inches Rating: 3phase/208volts/60Hz Run Time (hrs): 2523.7 (P1)

1814.0 (P2) Frame:

Actuating Controls: Bubbler Tube/Compressor system and back-up high water float Operating Controls: Controls Field Service (Job # 1007) Stand-by Generator Manufacturer:

Kohler Sump Pump Manufacturer:

Hydromatic

Model: 18RY/RZ Rated Capacity: Not listed Serial Number: Unknown Size: 20 kW Heater: N/A Engine: Ford Dehumidifier: N/A Run Time (hrs): Unknown Fuel: Natural Gas Fuel Tank Size: N/A Data Sources:

1 Information taken from equipment tag or nameplate during 2014 site visits. 2 Information taken from 2012 evaluation by W&S CMR Division. 3 Operation & Maintenance Manual information provided by City of Gloucester.

4.2.3 Site Observations

During our site visit, visual inspection was conducted for station exterior, electrical panels, breakers, control panels, and wetwell walls and interior (topside inspection only). Also performed was miscellaneous inspection and operation of pumps and motors, check and gate valves, mechanical piping and standby generator. Run time information available from operator checklists at the time of our visit indicate that the Heritage Way PS operates approximately 42 minutes per day. At the rated capacity of the pumps this equates to approximately 3,400 gallons per day of wastewater. Forced drawdown testing was performed during our visit and resulted in observed discharge rates of approximately 37 gpm for Pump #1 and 21 gpm for Pump #2. Observed fill rate of approximately 2 gpm is included in the values above. It appears that both pumps are putting out



4-8

significantly less flow than the design rate of 80 gpm. It should be noted that a significant amount of grease/floating solids were evident during the time of our visit. Subsequent discussions with city staff have indicated that the City has previously identified the likely source of the grease/solids as the 12 Heritage Way property (as discussed under Section 2 of this report). We made the following general observations and identified the following deficiencies about the Heritage Way Pump Station.

General Mechanical

A significant amount of grease/solids was observed in the wetwell. The pumps are putting out significantly less flow than the design capacity for the pumps. The mechanical equipment is reaching the end of its useful service life (i.e. 20-years).


The power supply does not have electronic surge protection (TVSS) device protector. The power supply currently has old fashioned air gap type units.

The simplex bubbler tube system for level control should be replaced with a pressure transducer and back-up high water float. Back-up controls via timing relays should also be added to the station.

The pump control panel utilizes air pressure switches and old style controls relay logic. The electrical equipment does not have engraved plastic nameplates and NEC electrical

shock hazard or NFPA arc-flash warning labels. Alarms for the station are limited and should be enhanced to be TR #16 compliant. The outdoor electrical enclosure does not have a cooling exhaust fan. The air intake has

been caulked/spray foamed closed, likely due to bubbler tube lines freezing in the winter. The outdoor electrical enclosure is missing insulation. Without insulation the electric

heater in the enclosure is not effective. The standby engine/generator does not have a remote Emergency Power Off (EPO)

control station. The city has indicated that the standby engine/generator for the site is non-functional and will be separately replaced with a new unit in the future. Costs for generator improvements have not been carried as part of the recommendations for this project.

The automatic transfer switch could not be verified to have “out of phase” protection on their “live” to “live” power supply transfers.

The conduits from the wetwell to the outside electrical junction boxes do not have cable/conduit seals.

Structural

Precast concrete wetwell and valve vault appear to be in sound condition. Safety Considerations

A “ladder up” type safety device should be added to the valve vault to improve safety/access to the structure.



4-9

A significant amount of yellow jackets/nests were observed in and around the engine/generator enclosure.

The lift hooks for wetwell and valve vault were never removed following installation and they are a trip hazard.

4.2.4 Recommendations

Based on the completed evaluation, we recommend that the following items be addressed to improve the reliability and safety of the pump station. Recommendations have been prioritized into short term (1 to 3 year) and long term (greater than 3 year) recommendations. Short Term Recommendations

General Mechanical

Evaluate the upstream and downstream collection system for clogging related to the high grease/solids loading observed in the wetwell.

Evaluate the condition of the forcemain for the station, as clogging may be resulting in significantly less than design rate pumping outputs observed. It should be assumed that the force main requires “pigging”.

The existing pumps are nearing the end of their useful life and should be replaced.


Add engraved plastic nameplates, NEC electrical shock hazard and NFPA arc-flash warning labels.

Add submersible level sensor and current relays plus secondary pump controls to the existing pump control panel.

Upgrade existing controls to SCADA capable system.

Structural No Recommendations Identified.


A “ladder up” type safety device should be added to the valve vault to improve safety/access to the structure.

The lift hooks for wetwell and valve vault should be removed. Yellow jackets inside the generator enclosure should be exterminated, and insect

screens checked and repaired as appropriate.

Long Term Recommendations

General Mechanical

No Recommendations Identified.

Electrical, Controls, Alarms No Recommendations Identified



4-10

Structural




4.2.5 Planning Level Cost of Improvements

Table 4-2 Heritage Way Pump Station Recommendations

Description of Recommendation Estimated

Cost Heritage PS - Short Term (1-3 years) General Mechanical u Evaluate the upstream and downstream collection system for clogging related to

the high grease/solids loading observed in the wetwell. $5,000

u Evaluate the condition of the forcemain for the station and "pig" the line. $5,000u Clean the wetwell $500u The existing pumps are nearing the end of their useful life and should be

replaced. $15,000

Electrical, Controls, Alarms u Add engraved plastic nameplates with voltage/phase with NEC electrical shock

and NFPA arc-flash warning labels to all electrical equipment. $200

u Add submersible level sensor and current relays plus secondary pump controls to the existing pump control panel.

$10,000

u Add SCADA control capabilities to the pump station $40,000 Safety Considerations u A "ladder up" type safety device should be added to the valve vault to improve

safety/access to the structure. $1,000

u Remove the lift hooks at the wetwell and valve vault. $250u The yellow jackets inside the generator enclosure should be exterminated. $250 Short-Term Needs Subtotal $78,000

Pump Station Subtotal $78,000

General Contractor Overhead & Mark-up (20%) $16,000

Engineering & Contingency (35%) $28,000

Pump Station Total $122,000

Summary The City of Gloucester should be replacing the existing Blackburn PS with a new submersible pump station with improved controls and dedicated standby generator in order to improve the operational efficiency of the station, increase station reliability and to meet the demands of the increased flow to the collection system from the Mazzetta Project. As there are at least two vacant/developable parcels in the Industrial Park which would tie into the Heritage Way PS, the city should be proactively improving that station to improve operational efficiencies and to restore the useful life of the equipment. The City of Gloucester should move forward with the



4-11

Short Term Recommendations for each station. A budget of approximately $533,000 (including 20% contractor overhead/profit and 35% engineering/contingency) should be allocated to improvements at the Blackburn PS and a budget of approximately $122,000 (including 20% contractor overhead/profit and 35% engineering/contingency) should be allocated to improvements at the Heritage Way PS.



5-1

5.0 ODOR CONTROL Odor control within the Blackburn Industrial Park and within the collection system will be important to limiting the amount of odor complaints within the industrial park and throughout the downstream collection system. Prior discussions with city officials have indicated that odor complaints had been present within the industrial park when Good Harbors was online. Good Harbors was previously utilized as a frozen fish processing facility. When the parcel is taken over by Mazzetta, the facility will be utilized as a lobster processing facility. Once Mazzetta is on-line, it is possible that odors will be present in the Blackburn PS wetwell and the downstream collection system once the pump station discharges flow to Harrison Avenue. The odors will mainly be released from the waste stream when dropping into the wetwell and when the forcemain from the Blackburn PS discharges to the collection system. Odors will need to be mitigated in the collection system as a result of this project, but at this time the exact nature and types of odors are unknown. It is recommended that the city test for the nature of odor compounds present once Mazzetta is on-line and operational. The city should maintain space at the Blackburn PS for two separate odor control systems. The first system will treat odorous air at the Blackburn PS wetwell through a biofilter or carbon type air filtration unit. The second system will be a chemical feed system which will inject a chemical into the wetwell in order to mitigate/control odors in the downstream collection system. The exact chemical to be introduced will be determined once more extensive testing is completed, but may be sodium hypochlorite, potassium permanganate, ferric chloride or another type of oxidizing chemical. A budgetary number of approximately $50,000 to $80,000 per system (including 20% contractor overhead/profit) should be allocated, $100,000 to $160,000 total. Adding in a 35% engineering and contingency factor results in an estimated project cost of $135,000 to $216,000. The costs presented assume that sufficient space is available for each system and legal/land procurement costs are not required to site the systems. The city will separately budget for odor control provisions for the pump station and collection system as a result of the new Blackburn Industrial Park project. Costs for odor control improvements have NOT been carried in the grant application package.



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6.0 SUMMARY The following is a general summary of the recommendations and associated costs of each of the five (5) report sections.

Section 1.0 – Per the terms of the agreement between the City of Gloucester and Mazzetta, 150,000 gpd of flow will be generated and equalized over a 24-hour period and discharged to the collection system. The City of Gloucester has allocated 1,000 lbs/day of BOD to Mazzetta.

Costs – No costs are associated with this.

Section 2.0 – By allocating 1,000 lbs/day of BOD to Mazzetta, the City of Gloucester has allocated 100% of their Maximum Allowable Industrial Load (MAIL) for BOD to facilities which currently are or will be monitored under the Industrial Pretreatment Program. The city should continue to evaluate all IPP permits as they come up for renewal and adjust loads as appropriate to maintain a “balance” of their MAIL. The city should work to include Custom Seasonings in the Industrial Pretreatment Program.

Cost - $60,000 should be allocated for engineering services associated with re-evaluating the existing City of Gloucester local limits, and working with US EPA to increase the maximum allowable industrial load (MAIL) for the city. This cost will be separately budgeted for by the city and is not included in the grant application package.

Section 3.0 – The city should extend the Blackburn PS forcemain discharge location by approximately 2,700-feet to the intersection of Eastern Avenue and Neptune Place in order to discharge to a larger diameter gravity sewer and alleviate a current surcharging issue which will be exacerbated by the increase in flow from the project.

Cost – A budget of $456,000 should be allocated to the forcemain extension to the intersection of Eastern Avenue and Neptune Place. The costs presented include an allocation for 20% contractor overhead and profit and 35% engineering/contingency.

Section 4.0 – Flow from the Mazzetta facility will be directed to the Blackburn PS prior to flows entering the downstream gravity collector system and being transmitted to the WPCF. The Blackburn PS is in need of a complete replacement in order to improve operational efficiency, restore useful life, increase station reliability and to meet the demands of increases in flow from the Mazzetta Project.

There are two vacant parcels in the Industrial Park which would tie into the Heritage Way PS, which also flows through the Blackburn PS. As the station’s equipment is nearing the end of its useful life, the city should move forward with the Short Term Recommendations.

Costs – The Short Term Recommendations for the Blackburn PS have an estimated cost of approximately $533,000 (including 20% contractor overhead/profit and 35% engineering/contingency).



6-2

The Short Term Recommendations for the Heritage Way PS have an estimated cost of approximately $122,000 (including 20% contractor overhead/profit and 35% engineering/contingency).

Short Term Recommendations at both pump stations total $655,000.

Section 5.0 – The city should maintain space for the installation of two separate odor control systems at the Blackburn Industrial Park, an activated carbon or biofilter type system and a chemical injection system. The systems should not be installed until Mazzetta is online and functional and the exact nature and types of odors present can be tested and evaluated.

Costs – The city will separately allocate a budget of between $135,000 and $216,000 (including 20% contractor overhead/profit and 35% engineering/contingency) for odor control systems at the Blackburn Industrial Park. Costs presented do not include legal or land fees associated with the procurement of easements. As these improvements will be separately budgeted for by the city, the costs for odor control provisions have not been included in the grant application.

Table 6-1 SUMMARY OF ESTIMATED COSTS Description Estimated Cost

Section 1 Flows and Loads Evaluation -

Section 2 Industrial Pretreatment and Local Limits $0.00*

Section 3 Downstream Surcharging $456,000

Section 4 Pump Station Improvements $655,000

Section 5 Odor Control $0.00*

ESTIMATED TOTAL COSTS $1,111,000

*Industrial Pretreatment/Local Limits and Odor Control provisions will be budgeted for separately by the City. The recommended improvements are appropriate for the City of Gloucester to invest in considering the importance of the business to the city as a new employer and tax payer. The city intends to seek funding for these necessary improvements under an economic development assistance grant from the US Economic Development Administration.



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7.0 PRELIMINARY ENGINEERING REPORT REQUIREMENTS

1.) Description of Project Components – Project Components are listed in the appropriate

sections of this report and are summarized in Section 6. 2.) Verification of Consistency with A.2 of Form ED-900 – The project components

described in this Preliminary Engineering Report are consistent with the Investment Project Description included in Section 1.2 of Form ED-900.

3.) Schematics of Project Components – Refer to Figure 6 of the Preliminary Engineering Report which shows the location, extents and costs associated with recommendations included in this Preliminary Engineering Report.

4.) Feasibility Analysis of Construction – Existing easement documents for the Blackburn Pump Station and the Heritage Way Pump Station indicate that sufficient space is available to move forward with the recommendations included in this Preliminary Engineering Report. The recommended forcemain extension will occur in the existing right-of-way for Harrison Avenue.

5.) Proposed Method of Construction – The City of Gloucester plans to move forward with the recommended improvements of this preliminary Engineering Report through a competitive bid process.

6.) Number of Construction Contracts – In order to move forward with the recommendations included in this Preliminary Engineering Report, the City of Gloucester plans to issue one contract package for soliciting bid quotes to perform the recommended improvements.

7.) Construction Cost Estimates – Estimates of cost for each recommendation are included in the appropriate sections of this Preliminary Engineering Report and are also summarized in Section 6.

8.) Property Acquisition – Based upon a review of existing easements at the wastewater pump station sites and the fact that the forcemain extension will occur within an existing right of way, no property acquisitions are required for the recommended improvements.

9.) Permits – As all work will occur on existing/previously disturbed parcels, no special permits other than city issued electrical and street opening permits are anticipated for the recommended improvements. Obtaining electrical and street opening permits will be a requirement of the selected contractor from the competitive bid process.

10.) Estimated Project Schedule – The engineering work associated with the recommended improvements can be completed in a three to four month period. Assuming an engineer is selected by June 2015, a bid package can be completed by October 2015. Bids are anticipated to be received in December 2015 and Contract Award is assumed to occur in January 2016. The contractor will be required to obtain required local electrical and street opening permits. Due to equipment lead time issues, it is estimated that construction will take approximately 180 days. Construction is anticipated to be complete by July 2016.



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CITY OF GLOUCESTER, MASSACHUSETTS

Blackburn Industrial ParkLOCUS MAP

OCTOBER 2014 SCALE: NOTED

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BLACKBURN INDUSTRIAL PARK AREATOPOGRAPHIC MAP


FIGURE 2

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BLACKBURN INDUSTRIAL PARK AREAZONING MAP


FIGURE 3ZoningBusiness Park

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FIGURE 4

FEMA Flood Zone DesignationsA: 1% Annual Chance of Flooding, no BFE

X: 0.2% Annual Chance of Flooding


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BLACKBURN INDUSTRIAL PARK AREA SENSITIVE HABITAT MAP


FIGURE 5Hydrologic Connections

Deep Marsh

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FIGURE 6CITY OF GLOUCESTER, MASSACHUSETTS

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BLACKBURN INDUSTRIAL PARKAREAS OF PROPOSED WORK

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$533,000 PS Improvements

$122,000 PS Improvements

2,700 LFForcemain Extension(Within Existing R.O.W.)$456,000

Friend Street

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Attachment 7 - Preliminary Engineering Report EDA ...

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Transcript of Attachment 7 - Preliminary Engineering Report EDA ...