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HomeMy WebLinkAboutItem #09 Approval of Replacement of Sludge Belt Press for Wastewater Treatment Plant AGENDA ITEM COVER SHEET Meeting Date: April 6, 2010 Item # 9 Contact Name: Contact Number: Charles K. Smith, P.E 407 -905-3159 Reviewed By: Department Director: Charle City Manager: Robert Fran Subject: Replacement of Sludge Belt Press for Wastewater Treatment Plant Background Summary: The Ocoee Wastewater Treatment Plant's existing sludge disposal method is accomplished by taking liquid sludge at 1 % sludge solids by weight, and pressing the sludge to 12-13% solids. The City's existing press was placed in service in 1994 and has been experiencing continuous failures, occasionally requiring sludge disposal through liquid hauling. The impact caused by the downed press and its age have necessitated a review of the City's disposal method. Sludge is composed of organic material (solids) and water; and based on the levels of treatment and pressing, different ratios of the solids-to-water are obtained. For analytical purposes, sludge samples should be considered based on the dry weight of the solids within the respective sample (comparing oranges to oranges). After review of fiscal year 2008/2009, it was determined that the City treated 516 tons of solids with 435 tons from pressed sludge and 81 tons from liquid. At the present contract price, it costs the City $322 to dispose of a pressed dry ton and $3,598 to dispose of a liquid dry ton. The City is exploring an opportunity to join into a cooperative with the City of Sanford that would reduce the liquid dry ton cost to $2,278. Clearly, pressing remains the most economical solution. To complete the review, first an assessment of the rehab or replacement of the sludge belt press was concluded. The press manufactured by I. Kruger Inc., the wastewater plant's bioprocess designer, cannot be rehabilitated and would require replacement; however, Kruger no longer markets their press in America. City Staff and the City's Engineering Consultant, Reiss Engineering, evaluated different presses essentially by exploring and confirming their specifications and results with other wastewater facilities. Staff visited sites including the Cities of Fernandina Beach, Apopka, Clermont, Mount Dora and Winter Garden, and also visited Orange County's Iron Bridge. Press types ranged from belt or rotary fan to centrifugal, and ranged in cost for equipment, not including installation, from $300,000 to $550,000. Construction costs would be an additional ~ of the equipment cost. The recommended selection is based on the Ashbrook Simon-Hartley Press that experienced an efficiency exceeding 16% sludge solids by weight. Referring to the 2008 tonnages, the above cost with this Ashbrook press (no liquid hauling) would be about $124,600 per year as opposed to $166,100 per year with the existing press. Staff is recommending the purchase of the best source Ashbrook Simon-Hartley Press, Klampress@, 2.0 Meter with an AB Conversion Kit, in association with its local factory sales representative, MTS, in the amount of $395,000. At this time, the City has the opportunity to join with the City of Sanford/MaxWest Inc. for a long-term sludge disposal alternative. The City currently uses a vendor that provides hauling and disposal through land spreading that is becoming more restrictive, is subject to discontinuation, and shall see increased costs due to regulatory requirements. The Sanford/MaxWest method of disposal is through incineration with the byproduct being ash that is not considered sludge. Again, referring to fiscal year 2008 tonnage for disposal, the Sanford/MaxWest disposal alternative would cost $161,200, negating savings obtained by the new press. MaxWest has indicated they would . consider, if the City elected their alternative, to provide terms within a .disposal agreement to establish the City's wastewater plant campus as a future regional site conditioned on "first right of refusal". Issue: Should Commission authorize the City Manager to purchase single/best source the Ashbrook Simon-Hartley Press, Klampress@, 2.0 Meter with an AS Conversion Kit, in association with it local factory sales representative, MTS in the amount of $395,OOO? Recommendations Motion to authorize City Manager to contract with Ashbrook Simon-Hartley Press and MTS to supply and install a Klampress@, 2.0 Meter with an AS Conversion Kit in the amount of $395,000; and authorize staff to further investigate contracting with the City of Sanford/MaxWest for sludge disposal. Attachments: Proposal from Ashbrook Simon-Hartley, Reiss Engineers Recommendation, 2008-2009 Ocoee Wastewater Plant Sludge Disposal/Hauling Summary Financial Impact: This press replacement was funded in this year fiscal budgeted at $325,000. Staff is recommending the use of saved funds from the Wastewater Plant SCADA upgrade of $40,000 (407-535-00-6400) and funds saved from the Reclaim High Service Pump Upgrade of $30,000 (401-535-00-6400) for a total $395,000. Type of Item: (please mark with an "x') Public Hearing Ordinance First Reading Ordinance Second Reading Resolution X Commission Approval Discussion & Direction For Clerk's Dept Use: _ Consent Agenda _ Public Hearing _ Regular Agenda Original Document/Contract Attached for Execution by City Clerk Original Document/Contract Held by Department for Execution Reviewed by City Attorney Reviewed by Finance Dept. Reviewed by ( ) ~f&-c;r N/A N/A N/A 2 ~ . REISS ENGINEERING PLANNING' DESIGN' CONSTRUCTION October 7, 2009 Charles Smith Director of Utilities Utilities Depaltment City of Ocoee 1800 A.D. Mims Road Ocoee, FL 34761 Re: Wastewater' Biosolids Dewatering Equipment Selection Engineer's Recommendation Dear Mr. Smith: This letter summarizes the City of Ocoee's independent engineer's recommendation for replacement of the City's biosolids dewatering equipment. As you are aware, the City cUl1'ently owns and maintains a 3.00 MGD wastewater treatment facility, which produces biosolids as a by-product from the activated sludge process. These biosolid generated in the activated sludge process require further treatment (stabilization) and subsequently require dewatering prior to final disposal off-site. The City's currcnt biosolids dewatering equipment (Kruger press) has been in continuous operation for over 15 years and has reached the end of its service life. As a result of the age and condition of the existing equipment, the City has been experiencing a significant decline in dewatering efficiency from the unit, which subsequently results in higher annual operating costs. As such, the City is proceeding with plans to replace the old unit with new, more efficient equipment. Reiss Engineering, Inc. (REI) was contracted by the City to providc a professional opinion regarding biosolids equipment dewatering options to provide the City with a recommendation for a reliable, proven equipment that will function properly and minimize biosolids dewatering costs for the next 12 to 15 years. REI reviewed standard commercially available biosolids dewatering equipment options, discussed these options with City operations statT. After our initial discussion with the City staff, REI and City staff jointly toured several local wastewater treatment facilities and interviewed operators at other facilities currently operating similar options. The City's needs included a minimum percent solids output of 12 percent, with the desire to achieve between 16 to 18 percent; and the ability in the future to operate in a thickening mode on a batch basis. Based on the work performed and concurrence fl'Om City operations staff, REI recommends the following equipment for installation: . Ashbrook Simon-Hartley Klampress 2 Meter Belt Filter Press. retrojittable in the future to a 3-belt COI?frgllration to allow operation ill either thickening or dewatering mode. Reiss Engineering, Inc. 12001 Research Parkway Suite 228 Orlando, FL 32826 Tel: 407.679.5358 Fax: 407.679.5003 www.reisseng.com This equipment was selected because of its significant proven track record on dewatering biosolids fi'om activated sludge processes at municipal wastewater treatment facilities in Central Florida. The City of Winter Garden, the City of Clermont, the City of Orlando, Orange County as well as numerous other central Florida Utilities and national locations have Ashbrook belt presses. The Ashbrook Klampress is a cost effective option as compared to other dewatering tec1ll1ologies and has a proven track record of equipment service. Please contact me if you need addition information regarding this information. Sincerely, EISS ENfINEP' ~IN.9'~. INiG. \. \ / \ \,. ~,A \ ('V~ ~~.'/ Gary . 'Weir, II, P.E. /1 Project~anager I March 9, 2010 AsIJblDDIt ~ SimDIJ-Hartley" To: Fred Ostrander City of Ocoee 1800 A.D. Mims Rd. Ocoee, FL 34761 Ashbrook Simon-Hartley 11600 East Hardy Houston, TX 77093 800-362-9041 Ref: Ocoee County, Florida Ocoee WWTP Ashbrook Budget Proposal Dear Sirs: On behalf of the Ashbrook Simon-Hartley Operations L. P. ("Ashbrook") and our local sales representative - MTS., we thank you for the opportunity to offer our budget proposal for your consideration on this project. The equipment we propose to furnish is as follows: QUANTITY DESCRIPTION (1) Ashbrook Simon-Hartley Klampress@, 2.0 Meter with an AB Conversion Kit. The gravity dewatering section shall be designed so that the unit can be operated as a gravity belt thickener. When operating in the thickening mode, the thickened sludge shall be directed to the thickened sludge hopper (supplied by others) by means of a thickened sludge discharge chute. The unit shall come complete with a machine-mounted hydraulic system for belt tensioning and tracking. (1) Main Control Panel, The Belt Filter Press (BFP) Control Panel will be designed, based on the emailed request from Mike McLaughlin (NO contract drawings). It will be powered from a 480 V AC power source, supplied by others. IEC style motor starters will be supplied for the washwater pump and hydraulic pump, with an Allen Bradley PowerFlex 400 style VFD provided for the belt drive motor. All other starters / controllers, and 120 V AC power for the polymer system will be supplied by others. The BFP Control Panel will be a NEMA 4X-304 Stainless Steel enclosure. The controls for the BFP and ancillary equipment will be either manually or automatically controlled. START/STOP pushbuttons with RUNNING status lights will be provided for control of the washwater pump/valve, the hydraulic pump, the belt drives, the belt conveyor, the sludge pump and the polymer pump. Speed control and speed/flow indication will be provided for the belt drive, the sludge pump and the polymer pump. Operator interface will be accomplished using Allen Bradley, Type 800H pilot devices. All logic will be performed via an Allen Bradley MicroLogix 1200 programmable logic Ocoee WWTP Ashbrook Budget Proposal Page 2 (1) (1) Lot (1) Lot (1) (1) Lot controller (PLC), with NO network communication capabilities. Inline, Non-Clog, Variable Orifice Mixer, one for each new press, and each complete with an injection manifold system and a four port vortex polymer injection ring. Field Service, a total of 3 trips and 12 days has been included in this proposal. Freight, this shall be to the jobsite. Polymer System, a Siemens model #@ M 1200-D4AA, PolyBlend M-Series polymer activation! feed system. Installation Services, to include: - Removal of existing press - Remove belt and horizontal portion of existing belt conveyor - Construct new 8" curb around outside of existing trench - Remove lower walkway and relocate higher walkway adjacent to new press - Install new press - Provide all new inlet piping and discharge chute as required, using as much of the existing as possible - Reinstall horizontal portion of belt conveyor and install new (owner provided) belt - Install all electrical asrequired for the new press - Remove existing polymer feed system - Install new polymer feed system including all required piping, supports and electrical Clarifications~ Exceptions & Recommendations: This proposal describes Ashbrook's understanding to provide a complete and operational new belt filter press and is based on a verbal request, site visit and conversations with the Director and other plant personnel. No drawings or specifications have been provided for guidance. No Spare parts have been included in this proposal. Unless otherwise specified in this proposal, all local motor disconnect devices and/or local motor lock- outs that may be required by a governing electrical code shall be provided and installed by others. Total price: $395.000, F.O.B. Houston, Texas, with freight allowed to jobsite. Taxes: The quoted price does not include any local, state or federal taxes, permits or other fees. Any taxes or fees that may apply must be added to the quoted price and paid by the buyer. Ocoee WWTP Ashbrook Budget Proposal Page 3 Note: Ashbrook Simon-Hartley is only registered to collect and remit sales tax in the following states: Texas, Louisiana, Florida, California, New Jersey, Indiana, Kentucky, Massachusetts, Ohio, and North Carolina. Taxable projects located in states outside these will need to accrue and pay these taxes direct to said state. Proposal Acceptance: This proposal is offered for acceptance within sixty (60) days from date of this quotation or date of bid opening, whichever is the later date. Prices are subject to review thereafter. Prices are firm, based upon receipt of a Letter ofIntent or Purchase Order and notice to proceed within this sixty (60) day period and the review and for return of submittal drawings to Ashbrook Simon-Hartley within thirty (30) days. Delays caused by slow return of submittals or other manufacturing delays caused by the contractor, owner, owner's agent or engineer may result in additional charges of I % per month for such delays or part thereof. Submittal Drawings: Mechanical submittal and drawings on the preceding equipment will be submitted in accordance with the required delivery date of the equipment and after receipt of a firm purchase order. Electrical (control panel) drawings will be submitted as noted above and after receipt of a firm purchase order. Note: A purchase order signed by both Ashbrook Simon-Hartley and the purchase order originator must be executed prior to any submittal being forwarded. Shipment: Delivery of the new units can be made in twelve to sixteen weeks from receipt of order. Early shipment of embedded metal work can usually be made, but will be shipped at the purchaser's expense. Payment Terms: Orders providing for retention of monies are not acceptable. Invoices are due and payable within thirty (30) days of any shipment made to the job site. Shipments such as embedded metal or partial items will be invoiced as shipped on a prorated price to be determined by Ashbrook Simon-Hartley. If shipment is delayed by Purchaser, Ashbrook Simon-Hartley may invoice and pass title to the Purchaser; Purchaser agrees to remit the amount due at the times stated, as if the equipment had shipped. All costs of storage shall be at the Purchaser's expense. Escalation Charges: In the event that delivery of equipment cannot be made on the scheduled delivery date agreed upon between Ashbrook and buyer and as evidenced by the terms of the contract, due to buyer delay, Ashbrook Simon-Hartley reserves the right to assess escalation charges to the project due to material price movement. Terms: Ocoee WWTP Ashbrook Budget Proposal Page 4 Ashbrook Simon-Hartley's Standard Terms and Conditions are enclosed and apply in their entirety. All applicable sales, use or other taxes are to be paid by buyer. If any taxes are to be paid by seller, the quotation price shall automatically be increased by the same amount. Failure to pay invoices promptly when due nullifies Ashbrook Simon-Hartley's obligation to perform work under warranty, installation and start-up in a timely manner. The contractor explicitly agrees that subject to acceptance by the consulting engineer and/or the owner, Ashbrook Simon-Hartley may substitute a stand-by letter of credit in lieu of cash retainages required in the plans and specifications and contract documents, and 100% of the cash released by such acceptance will flow through immediately to Ashbrook Simon-Hartley. All orders are subject to credit approval prior to acceptance of contract or purchase order. Again, we thank you for the opportunity to offer this proposal. Should you have any questions, please feel free to contact us, or our representative noted below. Sincerely, Carr (]3oycf Marketing Manager Biosolids YWikf YWcLaugliEn Regional Manager cc: MTS, Inc. Ocoee WWTP Ashbrook Budget Proposal Page 5 STANDARD TERMS AND CONDITIONS (STD TRM&CND Rev 5. 2Mar09) ACCEPTANCE: These Standard Terms and Conditions shall apply and form part of the attached quotation except as expressly otherwise agreed to in writing by Buyer and an authorized representative of ASHBROOK S[MON-HARTLEY OPERATIONS, LP ("Ashbrook"). Unless otherwise expressly stated herein, this proposal shall expire thirty (30) days after its issuance date. This proposal is offered for acceptance within thirty (30) days from the date of its issuance or date of bid opening, whichever is the later date. Prices are subject to review thereafter. Prices are firm, based upon receipt of an executed Purchase Order and notice to proceed within this thirty (30) day period. Given the current volatility in commodity prices, Ashbrook has made this proposal based upon shipment of the offered products contained herein within the schedule dictated above. Should the projected shipment schedule fall outside this period for any reason, pricing shall be subject to review and revision. DELIVERY: Except as otherwise specified in this quotation, delivery will be Ex-Works, Houston, Texas. Time of delivery is an estimate only and is based upon the receipt of all information and necessary approvals within a timely manner. Ashbrook shall in no event be liable for delays caused by acts of force majeure, including but not limited to fires, acts of God, strikes, labor difficulties, acts of governmental or military authorities, delays in transportation or procuring materials, or causes of any kind beyond Ashbrook's control. WARRANTY: The equipment offered is warranted in accordance with the terms of Ashbrook's standard warranty which is hereby made part of this proposal. PRICES/TAXES: All quoted prices exclude any local, state or federal sales, use, occupation, license, excise and/or other taxes or fees with respect to the manufacture, sale and/or delivery of equipment and services, all of which shall be paid by the Buyer. TERMS: [f not otherwise specified in the proposal, the terms of payment shall be net thirty (30) days after invoice. [n all cases payment, other than initial payments, shall be made pro rata as principal items are shipped. [n the event delay in making shipment is caused by Buyer, payment for such shipment shall be due thirty (30) days from date Ashbrook notifies Buyer that Ashbrook is prepared to make such shipment. If Buyer delays completion of manufacture, Ashbrook may elect to require payment according to percentage of completion. Equipment held and stored for Buyer shall be at Buyer's risk and expense. CANCELLA TION: In the event the Buyer elects to cancel the order or if any proceeding be instituted by or against Buyer under any bankruptcy or insolvency law, or if in Ashbrook's judgment, Buyer's financial situation justifies such action, Ashbrook may, at it's election exercisable at any time prior to equipment delivery require payment in advance or cancel the order as to any unshipped items and require payment of its reasonable cancellation charges in accordance with the following schedule: Milestone Prior to Submittal Subsequent to Submittal Approval Subsequent to Release to Production Subsequent to Initiation of Equipment Assembly % of Order Value 10% 20% 75% [00% BACKCHARGE/CHANGE ORDERS: Ashbrook shall not accept any backcharges unless written approval has been furnished to and approved by an authorized Ashbrook representative prior to the commencement of such work. No changes shall be made and no adjustments to the proposal price shall be due except upon the execution of a written change order between the Buyer and Ashbrook. TITLE AND LIEN RIGHTS: The equipment shall remain personal property, regardless of how affixed to any realty or structure and Ashbrook shall keep a secured interest in said equipment until the price of the equipment has been fully paid in cash. Ashbrook shall, in the event of Buyer's default, have the right to repossess such equipment. LIABILITY: In no event shall Ashbrook be liable for damages or injuries of any kind, including but not limited to incidental, consequential, direct or indirect damages, resulting from or caused by any product furnished or service provided by Ashbrook. Consequential damages for the purposes of this agreement shall include, but not be limited to, loss of use, income or profit, or loss of or damage to property occasioned by or arising out of the operation, use, installation, repair or replacement of the equipment or otherwise. THIS QUOTATION MAY BE CHANGED, REVOKED AND/OR WITHDRAWN BY ASHBROOK AT ANY TIME UPON WRITTEN NOTICE TO THE BUYER. Ocoee WWTP Ashbrook Budget Proposal Page 6 ASHBROOK SIMON-HARTLEY OPERA nONS, LP (" ASHBROOK") (STD TRM&CND Rev 5, 2Mar09) SER VICE TERMS I. Rates Domestic Rates (Continental U.S.) Service Technicians Process Technicians Process Engineers Monday-Friday $ 950/day $1, ISO/day $1,950/day International Rates Service Technicians Process Technicians Process Engineers $1,150/day $ I ,350/day $2, ISO/day Above rates are based on an 8-hour man-day during normal working hours and are in U.S. Dollars. Travel time is included as working time. All overtime, in excess of 8 hours per day worked and Saturdays, shall be billed at time and a half. Sundays and U.S. holidays shall be billed at double time. Parts and expenses billed additionally. Payment Terms - payable immediately upon receipt of invoice. Service may be refused to any area designated as High Risk by Ashbrook, such refusal shall take precedence over any other agreed terms. 2. Minimum Billing A minimum charge of 1/2 day's time shall be billed. Billing shall be made in 1/2 day increments for time each day at job and/or traveling during normal working hours. For example, five hours spent on job and/or traveling to jobsite shall be billed as one full 8- hour day. 3. Normal Working Time Eight hours per day with one hour for lunch, Monday - Friday, except observed U.S. holidays. 4. Travel Travel arrangements are made with 14-day advance purchase. Should the agreed travel dates change due to no fault of Ashbrook and additional costs be incurred, such costs shall be chargeable to the Customer. Travel expenses include but are not limited to: · Plane fares, train fares and/or automobile rental to and from Ashbrook's facility in Houston, Texas, to the Customer's plant or jobsite. . Private automobile travel at the current IRS published rate. . Expenses, tolls and fares associated with all local travel. . Living expenses for lodging, meals and incidental costs. . Telephone calls and wires, as required in connection with the details of the service. · When Ashbrook's technician goes from job to job rather than returning to his headquarters, an equitable distribution of the travel charges shall be made. A 20% overhead charge will be added on all travel and living expenses. 5. Parts All parts supplied shall be billed at Ashbrook's list selling prices. Service work by others under our authorization shall be billed at our cost plus 20% overhead. 6. Limits of Liability While Ashbrook's technicians are authorized to work on Ashbrook equipment, all responsibility for operation remains and rests with the Customer. In no event shall Ashbrook be liable for damages or injuries of any kind, including but not limited to incidental, consequential, direct or indirect damages, resulting from or caused by any product furnished or service performed by Ashbrook. Consequential damages for the purposes of this agreement shall include, but not be limited to, loss of use, income or profit, or loss of or damage to property occasioned by or arising out of the operation, use, installation, repair or replacement of the equipment or otherwise. 7. Authorization Ashbrook shall not make any travel arrangements or commence any service'work until an executed Purchase Order for the work has been received from the Customer. Ocoee WWTP Ashbrook Budget Proposal Page 7 WARRANTY(STD TRl\I&CND Rev 5, 2Mar09) ASHBROOK SIMON-HARTLEY OPERATIONS, LP ("Ashbrook") warrants for a period of twelve (12) months from start up, not to exceed eighteen (18) months from date of shipment, the new equipment of its own manufacture to be free from defects in material and workmanship under normal use and service when used and maintained in accordance with Operation and Maintenance Instruction Manual supplied by Ashbrook. Ashbrook's obligation under this warranty being limited to repairing or replacing, at its option, any part found to its satisfaction to be defective, providing that such part is, upon request, returned to Ashbrook's factory, freight prepaid. This warranty does not cover parts damaged by decomposition from chemical action or wear caused by abrasive materials, nor does it cover damage resulting from misuse, accident, neglect or from improper operation, maintenance, installation, modification, or adjustment. This warranty excludes consumable parts, which are warranted for a period of thirty days from start up. THIS IS ASHBROOK'S SOLE WARRANTY WITH RESPECT TO THE SUPPLIED EQUIPMENT. ASHBROOK MAKES NO OTHER WARRANTY OF ANY KIND WHATSOEVER, EXPRESS OR IMPLIED, AND ALL WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR/INTENDED PURPOSE ARE HEREBY DISCLAIMED BY ASHBROOK AND EXCLUDED. Ashbrook shall not be liable for indirect or consequential damages, whether or not caused by its neglect. Consequential damages for the purposes of this agreement shall include, but not be limited to, loss of use, income or profit, or loss of or damage to property occasioned by or arising out of the operation, use, installation, repair or replacement of the equipment or otherwise. Ashbrook's liability under no circumstances shall exceed the contract price for equipment claimed to be defective or unsuitable. "Start up" for the purpose of this agreement shall be the date when the equipment is first placed into operation regardless of the status of other items, i.e. sludge feed systems, polymer feed systems, conveyors, etc., at that time. All parts repaired or replaced under this warranty shall continue coverage on a prorated basis of the original warranty. Ashbrook shall in no event be liable for damage caused by acts of force majeure, including but not limited to acts of war, fires, acts of God, strikes and labor difficulties, acts of governmental or military authorities, civil unrest, or causes of any kind beyond Ashbrook's control. Service may be refused to any area designated as High Risk by Ashbrook. This refusal shall take precedence over any other agreed terms. o If !... E ~ o ~ ~. ~ :: O.....~~.., ~n~u iiif~illllllll illl Ii E~::: --0, ~H Q~ U ". '0, n '" ..,,,, 8 '" ... ... ... ...... 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