Budget Message / Highlights - Metropolitan Water Reclamation ...

Budget Message / Highlights - Metropolitan Water Reclamation ... Budget Message / Highlights - Metropolitan Water Reclamation ...

19.01.2015 Views

METROPOLITAN WATER RECLAMATION DISTRICT OF GREATER CHICAGO 2009 BUDGET MAINTENANCE & OPERATIONS – STICKNEY SERVICE AREA 2009 BUDGET NARRATIVE (continued) • 07-168-3P, Scum Concentration, Post Centrifuge Building, Preliminary Tank and Elevator Improvements - Deteriorated sludge boxes in preliminary control houses will be replaced. The drain valves in scum concentration tanks are also scheduled for replacement. The new drain valves will better allow for tank draw down in the event of required maintenance; • 02-111-3M, Rehabilitation of Mainstream TARP Pumps -The pumps have been in service since 1985 and need to be rehabilitated to restore original conditions. The pumps are not operating at optimum capacity or efficiency; • 07-163-3M, R&D HVAC Improvements - Replace aging supply and exhaust air handling units, chillers, ductwork and four cooling towers to improve conditions at the R&D facility. BIOSOLIDS In 2009, the Stickney Biosolids Operation was transferred to the General Division. This realignment has allowed for consolidated work efforts under a united Solids Management Area, with the primary goal to minimize costs. The Alternative Biosolids Processing Facility began operations in the fall of 2008. This operation will produce a pellet-type product. The pelletizer operation will gradually lower lagoon inventories and dry utilization. For 2009, we anticipate that the pelletizer operation will produce 54,600 dry tons of product. ENERGY MANAGEMENT, “GREEN” AND MASTER PLAN RELATED INITIATIVES The Plant Engineering, Maintenance and Operations teams have eagerly pursued energy management excellence, while looking for ‘green’ opportunities as they become available. We have convened both a Natural Gas Committee, as well as an Energy Conservation Committee, to study and implement efficiencies. Stickney WRP expects the delivery of all-electric personnel carriers. The plan is to continue this movement, and look to allelectric and hybrid alternatives first, when evaluating future needs. Much of the regular maintenance work also improves efficiency. For example, projects such as: the Boiler Rehabilitation Program, the overhaul of Process Blower #7, the rehabilitation of rotating assemblies at Racine Avenue Pump Station, pumps at Main Stream not only extend the useful life of the equipment and lessen the probability of critical failure, but they result in reduced energy consumption. Reduced energy consumption, through modernization, procurement and installation of the next generation of pre-digestion sludge centrifuges (XM-905) begins in 2009. The new assemblies will use less than 50% of the energy as compared to the existing equipment (PM-95000), and can process double the flow of bio-solids (WAS) flow. These same XM-905 centrifuges will provide sufficient treatment capacity such that a planned facility expansion will not be required. Additionally, the conversion of Imhoff Tanks to round primary tanks, the addition of round primary sludge concentration tanks and other Master Plan items will provide paybacks in terms of increased digester gas production and reduced maintenance costs. MAJOR M&O CONTRACT WORK FOR 2009 • Continue various maintenance programs, such as painting final tanks, tank rehabilitation, plant HVAC maintenance, boiler maintenance, ozone generator repairs, centrifuge rotating assembly repairs; • Rehabilitate a rotating assembly at the Racine Avenue Pump Station; • Continue repair program for South West Main Sewage Pump 66-inch Discharge Valves; • Continue conversion of the Primary Tank flight chains from carbon steel to stainless steel; • Replace leaky diffuser piping in the primary tank area to meet treatment objectives and save energy; • Install one high-effiency air compressor to replace existing units that are approaching the end of their expected useful life, It is anticipated that this will reduce energy consumption and maintenance costs by approximately $20,000 per year; • Continue preparation of ERMS and Title V Annual Emission Reports; • Install next generation pre-digestion centrifuge rotating assemblies which have higher outputs and use less energy; • Continue assisting IRB with various inventory reduction projects and establishment of material reorder points and transfers that result in inventory reduction; • Repair Main Stream Pumping Station main sewage pump discharge valve #4 to ensure low head pump availability; 308 308

METROPOLITAN WATER RECLAMATION DISTRICT OF GREATER CHICAGO 2009 BUDGET • Inspect/clean Westside wet well to address liquid vortexing and pump cavitation problems, and reduce the frequency of major maintenance required on impellers, wear rings, and casings; • Conduct Arc Flash training and procurement/rental of protective gear in accordance with NFPA 70E ; • Rehabilitate the Main Stream Pumping Station (MSPS) dewatering and discharge valve chamber cranes; • Retrofit post centrifuge back-drive motor to improve reliability and increase useful life; • Replace 400kW portable emergency generator; • Continue sewage collection/treatment and biosolids processing, all within the limits of our NPDES Permit; • Pelletizer Facility in full operation and related operational changes Division-wide to accommodate and make use of the efficiencies created by the new facility; • Continue to cooperate with Engineering for additional Sewer Rehabilitation such as the lining of Salt Creek #3 in LaGrange Park; • Building rehabilitation program to comply with GASB 34, including rehabilitating the Battery C Gallery; • Under assistance of M&R, SWRP Building & Grounds plans to revise the SWRP landscape contract in order to reduce the use of chemicals and ultimately utilize more environmental friendly materials; • Improve snow removal/de-icing by using environmental friendly approaches; • Continue railroad track, railroad car, and locomotive preventative maintenance and repair. 2008 ACCOMPLISHMENTS • Rehabilitated a rotating assembly at Racine Avenue Pump Station; • Procured services and parts to repair Southwest Main Sewage Pump 66-inch Discharge Valves; • Continued program to procure and replace WS Main Sewage Pump cast iron rotating elements with stainless steel, which are estimated to last at least three times longer than cast iron; • Installed new pneumatic controls in the Aerated Grit Pump Gallery to isolate the gallery from the tanks in order to prevent flooding during any potential pipe failure; • Procured four pre-digestion centrifuge rotating assemblies. The new design of the assemblies will result in higher output and significantly lower energy usage; • Replaced existing audible gas alarm with Federal Select Tone – Standardize alarm throughout plant; • Replaced regular AC source to flashing lights with solar panels for increased reliability and decreased maintenance labor costs at Location 13A PS Railroad Crossing; • Replaced hard-wire with wireless communication systems for increased reliability and decreased maintenance labor costs for West Side Overflow Bypass; • Upgraded UPS system at the MSPS to increase reliability, minimize outages and costs of repairs; • Replaced surge arrestors on Main Sewage Pumps at MSPS to eliminate costly motor breakdowns and increase equipment reliability; • Replaced outdoor surveillance cameras with pan, tilt and zoom dome cameras. The new units will decrease downtime and maintenance costs as well as enhance security at the Stickney Water Reclamation Plant; • Installed control panel for the air compressors city water break tank. This will provide an additional source of cooling water for the air compressors at the Pump & Blower House in the event effluent water become unavailable; • Registered elevators with the Illinois State Fire Marshall, completed inspections, and plans for updates for elevators in order to comply with the Illinois Elevator Safety Regulation Act; • Installed two additional ammonia analyzers in Aeration Batteries B and C to improve plant operability. This equipment will be included in the new DCS, per our request to Engineering; • Earned the National Association of Clean Water Agencies Platinum Peak Performance Award. This honor is in recognition of complete and consistent NPDES permit compliance, and the receipt of Gold Awards for five concurrent years; • Continued the Bubbly Creek drawback operations which allows for movement of water in this portion of the river system to help contain odor emissions; • Installed odor control unit at 43 rd Street and East Avenue per study recommendations; • Continued building rehabilitation program to meet GASB 34 goals: Battery B Gallery rehabilitation and a new roof at Mainstream Pump Station; • Worked with District Police staff to improve SWRP security through fence and monitoring enhancements; • Maintained Natural Prairie Landscape Area – 13.5 acres installed at Stickney WRP and MSPS; 309 309

METROPOLITAN WATER RECLAMATION DISTRICT OF GREATER CHICAGO<br />

2009 BUDGET<br />

• Inspect/clean Westside wet well to address liquid vortexing and pump cavitation problems, and reduce the frequency of<br />

major maintenance required on impellers, wear rings, and casings;<br />

• Conduct Arc Flash training and procurement/rental of protective gear in accordance with NFPA 70E ;<br />

• Rehabilitate the Main Stream Pumping Station (MSPS) dewatering and discharge valve chamber cranes;<br />

• Retrofit post centrifuge back-drive motor to improve reliability and increase useful life;<br />

• Replace 400kW portable emergency generator;<br />

• Continue sewage collection/treatment and biosolids processing, all within the limits of our NPDES Permit;<br />

• Pelletizer Facility in full operation and related operational changes Division-wide to accommodate and make use of the<br />

efficiencies created by the new facility;<br />

• Continue to cooperate with Engineering for additional Sewer Rehabilitation such as the lining of Salt Creek #3 in<br />

LaGrange Park;<br />

• Building rehabilitation program to comply with GASB 34, including rehabilitating the Battery C Gallery;<br />

• Under assistance of M&R, SWRP Building & Grounds plans to revise the SWRP landscape contract in order to reduce the<br />

use of chemicals and ultimately utilize more environmental friendly materials;<br />

• Improve snow removal/de-icing by using environmental friendly approaches;<br />

• Continue railroad track, railroad car, and locomotive preventative maintenance and repair.<br />

2008 ACCOMPLISHMENTS<br />

• Rehabilitated a rotating assembly at Racine Avenue Pump Station;<br />

• Procured services and parts to repair Southwest Main Sewage Pump 66-inch Discharge Valves;<br />

• Continued program to procure and replace WS Main Sewage Pump cast iron rotating elements with stainless steel, which<br />

are estimated to last at least three times longer than cast iron;<br />

• Installed new pneumatic controls in the Aerated Grit Pump Gallery to isolate the gallery from the tanks in order to prevent<br />

flooding during any potential pipe failure;<br />

• Procured four pre-digestion centrifuge rotating assemblies. The new design of the assemblies will result in higher output<br />

and significantly lower energy usage;<br />

• Replaced existing audible gas alarm with Federal Select Tone – Standardize alarm throughout plant;<br />

• Replaced regular AC source to flashing lights with solar panels for increased reliability and decreased maintenance labor<br />

costs at Location 13A PS Railroad Crossing;<br />

• Replaced hard-wire with wireless communication systems for increased reliability and decreased maintenance labor costs<br />

for West Side Overflow Bypass;<br />

• Upgraded UPS system at the MSPS to increase reliability, minimize outages and costs of repairs;<br />

• Replaced surge arrestors on Main Sewage Pumps at MSPS to eliminate costly motor breakdowns and increase equipment<br />

reliability;<br />

• Replaced outdoor surveillance cameras with pan, tilt and zoom dome cameras. The new units will decrease downtime and<br />

maintenance costs as well as enhance security at the Stickney <strong>Water</strong> <strong>Reclamation</strong> Plant;<br />

• Installed control panel for the air compressors city water break tank. This will provide an additional source of cooling<br />

water for the air compressors at the Pump & Blower House in the event effluent water become unavailable;<br />

• Registered elevators with the Illinois State Fire Marshall, completed inspections, and plans for updates for elevators in<br />

order to comply with the Illinois Elevator Safety Regulation Act;<br />

• Installed two additional ammonia analyzers in Aeration Batteries B and C to improve plant operability. This equipment<br />

will be included in the new DCS, per our request to Engineering;<br />

• Earned the National Association of Clean <strong>Water</strong> Agencies Platinum Peak Performance Award. This honor is in recognition<br />

of complete and consistent NPDES permit compliance, and the receipt of Gold Awards for five concurrent years;<br />

• Continued the Bubbly Creek drawback operations which allows for movement of water in this portion of the river system<br />

to help contain odor emissions;<br />

• Installed odor control unit at 43 rd Street and East Avenue per study recommendations;<br />

• Continued building rehabilitation program to meet GASB 34 goals: Battery B Gallery rehabilitation and a new roof at<br />

Mainstream Pump Station;<br />

• Worked with District Police staff to improve SWRP security through fence and monitoring enhancements;<br />

• Maintained Natural Prairie Landscape Area – 13.5 acres installed at Stickney WRP and MSPS;<br />

309<br />

309

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