IRWD Michelson Water Recycling Plant Phase 2 Expansion
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Transcript of IRWD Michelson Water Recycling Plant Phase 2 Expansion
© 2015 HDR, all rights reserved.
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Irvine Ranch Water District’sMichelson Water Recycling PlantPhase 2 Expansion
MBR Overview
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December 3rd 2015
Potable Water67% Groundwater & 33% Imported Water
Sewage Collection & Treatment35.5 MGD of Title 22 recycled water capacity
Recycled/ Non-potable WaterIrrigation, high-rise building toilet flushing, industrial use
Urban Runoff TreatmentMan-made wetlands to treat dry weather
runoff and first flush
Irvine Ranch Water District
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About the Irvine Ranch Water District California Special District governed by a publicly-elected Board
IRWD customer base• Residential population: 390,000• Daytime population: over 500,000• Service connections: 105,688
IRWD service area• 181 square miles (20% of Orange County)• All or part of six cities and unincorporated county
IrvineTustin
Orange
Lake ForestNewport Beach
Costa Mesa
Phase 2 Expansion increased capacity by 10 MGD from 18 MGD to 28 MGD
Existing plant produces approximately 20 MGD of Title 22 recycled water for unrestricted landscape irrigation
Michelson Water Recycling Plant
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Floodwall – 200 Year Flood Protection
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Alternative 1:Expansion of Existing Biological Treatment and Filters
MWRP Phase 2 Treatment Alternatives
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Alternative 2:Parallel Membrane Bioreactor Train
Alternative 1 – Expansion of Existing Biological Treatment and Filters
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Existing Activated
Sludge Train
NewActivated
Sludge TrainFLOW
EQUALIZATIONBASIN
ExistingConventional
Filters
Primary Effluent
Add three new aeration basins and four new circular clarifiers Expand filtration
ExpandedConventional
Filters
Disinfection
Alternative 2 – Parallel Membrane Bioreactor Train
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Add new 10 MGD membrane bioreactor process Parallel to existing activated sludge train
Existing Activated
Sludge Train
Existing Conventional
Filters Disinfection
Membrane Bioreactor
Primary Effluent
FLOWEQUALIZATION
BASIN
Evaluation and Selection
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Non-Economic and Economic Criteria Non-Economico Technical Performanceo Operation and Maintenanceo Integration with Existing and New
Facilitieso Implementation Requirementso Environmental Impacts
Economico Capital and Operation & Maintenance
Costso Life Cycle Cost Analysis
Alternative 1 Evaluation – Expansion of Existing Biological Treatment and Filters
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Advantageso Matches current process configuration &
hydraulic profileo Least number of new unit processes
(simplest operation)o Lower construction and operational cost
Disadvantageso Difficult to implement and phase constructiono More residuals for disposalo Less compatible with potential future treatment
requirementso Footprint requirements may impact other facilities
Alternative 2 Evaluation – Parallel Membrane Bioreactor Train
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Advantageso Best water qualityo Best ability to comply with future
regulatory changeso Best ability to accommodate
TDS removalo Smaller footprinto Easiest implementation, ability to
phase constructiono Greatest reuse flexibilityo Lower residuals flow
Disadvantageso Higher construction costo Operational complexity associated with
membrane facilityo Potential long-term reliance on single
membrane supplier
Economic Evaluation – Life Cycle Cost
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$64.4M$58.6M
2010 2015 2020 2025 2030$0M
$20M
$40M
$60M
$80M
$100M
$120M
$140M
$160M
Year
Cap
ital a
nd O
&M
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ts
Alt. 1 – Expanded Activated Sludge and Conventional Filtration
Alt. 2 - Parallel MBR with Act. Sludge and Conventional Filtration
Construction Cost (typ)
Combined Treatment Systems
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Michelson Water Recycling PlantExisting Treatment Process
NORTH IRVINE INTERCEPTOR
SOUTH IRVINE INTERCEPTOR
INFLUENT GRINDERS
PRIMARY SEDIMENTATION
TANKS
FLOW EQUALIZATION BASINS
ACTIVATED SLUDGE BASINS
SECONDARY SEDIMENTATION
TANKS
DUAL MEDIA
FILTERSCHLORINE CONTACT
TANKS
RECYCLED WATER CUSTOMERS
OCSD
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Increase capacity to approximately 28 MGD Completed 2015 Expansion included
o New Influent Sewerso New Headworkso Expanded Primary Sedimentation Tankso Expanded Flow Equalization Facilitieso Upgrades to Conventional Activated
Sludge Processo New High Rate Clarifiero New Membrane Bioreactoro New Ultraviolet Disinfection Facilityo Upgrades to Chlorine Contact Basino Expansion of Recycled Water Pump Stationo New Chemical Facilitieso New Electrical Facilities
Phase 2 Expansion
Phase 2 Expansion Overview
`
HEADWORKSNEWPSTs
EXISTINGPSTs
PEPS
MEMBRANE BIOREACTOR
FLOWEQUALIZATION
BASINS
EXISTINGBLOWER
ROOM
HIGH RATECLARIFIER
UV DISINFECTION
SPENT BACKWASH TANK
CHLORINE CONTACT TANK
EFFLUENT PUMPS
NEW TREATMENT FACILITIESMODIFIED EXISTING TREATMENT FACILITIESNEW CHEMICAL FACILITIESNEW ELECTRICAL FACILITIES
SPENT BACKWASH TANK
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Michelson Water Recycling PlantPhase 2 Treatment Process
OCSD
NORTH IRVINE INTERCEPTOR
SOUTH IRVINE INTERCEPTOR
HEADWORKS
PRIMARY SEDIMENTATION
TANKS
FLOW EQUALIZATION BASINS
ACTIVATED SLUDGE BASINS
SECONDARY SEDIMENTATION
TANKS
DUAL MEDIA
FILTERS
CHLORINE CONTACT TANKS RW
CUST.
HIGH RATE CLARIFIER
UV DISINFECTIONMEMBRANE BIOREACTOR
PRIMARY EFFLUENT
PUMP STATION
Evaluation and selection of membrane manufacturer
Pre-purchase of membrane equipment Design around GE/Zenon
ZeeWeed 500D WastewaterMembranes
$9M for 10.6 MGD flow or 1,080,000 sq ft of membranes
Membrane Bioreactor Design
Michelson Water Recycling PlantMembrane Bioreactor
FINE SCREENS
BIOLOGICAL REACTORS
MEMBRANE TRAINS
PERMEATE PUMP ROOM
BLOWER ROOM
FINE SCREENS
ANOXIC ZONES DEOXYGENATION ZONES
AEROBIC ZONES
ANOXIC ZONES DEOXYGENATION ZONES
AEROBIC ZONES
REACTOR 7
REACTOR 8
MIX
ED
LIQ
UO
R
PU
MP
STA
TIO
N
RA
S
BO
X MEMBRANE TANKS
PE
RM
EAT
E P
UM
P R
OO
M
BLO
WE
R R
OO
M
DIP TANK
B.P. TANK
RA
S C
HA
NN
EL
Michelson Water Recycling PlantMembrane Bioreactor
FINE SCREENS
BIOLOGICAL REACTORS
MEMBRANE TRAINS
PERMEATE PUMP ROOM
BLOWER ROOM
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Maintain existing plant capacity and operation.
Identify hydraulic and electrical tie-ins.
Set limits on shutdown durations. Detailed sequence for establishing
biomass. Detailed functional testing.
Construction Sequencing
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Proper storage - conditioned space.
Educate crew on sensitive nature of the membranes.
Membrane Trackingo Serial Numbero Moisture / Temperature historyo Installed locationo Damaged strandso Permeability history
Training during startup. Membrane Tank Access. Bridge Crane Design.
Membrane Handling and Tracking
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Create continuous unobstructed path for foam. Avoid traps/dead ends.
Foam removal is continuous. Mixed Liquor internal bypass allows
Mixed Liquor Re-screening.
Foam and Mixed Liquor Management
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GE’s standard programming results in a pulsed flow pattern.
Discovered during commissioning. Impacts to downstream processes,
primarily UV disinfection.
Permeate Flow Variation
Permeate Flow Before Reprogramming
Permeate Flow After Reprogramming
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Phase 2 Project Cost
MBR Construction $ 36 Million
Other MBR Related (Electrical Bldg) $ 21.5 Million
Other Treatment Processes $ 31 Million
Overall Construction Cost $ 88.5 Million
Change Orders $ 5 Million (5.6%)
Construction Total $ 93.5 Million
Construction Management $ 11.5 Million (12%)
Design $ 13.4 Million (14%)
Other $ 15.3 Million
Project Total $ 133.7 Million
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MBR Operation and Maintenance Cost
Electrical Power $ 453/MG
Chemicals $ 3/MG
Operations Labor $ 71/MG
Maintenance (electrical & mechanical) $ 38/MG
Total $ 565/MG
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Questions
Gregorio Estrada, P.E.HDR Engineering, Inc.3230 El Camino Real, Suite 200Irvine, California 92602(714) 730-2391 office(714) 292-5494 [email protected]
Steve Malloy, P.E.Irvine Ranch Water District3512 Michelson DriveIrvine, California 92612(949) 453-5695 office(949) 439-1816 [email protected]