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Home My WebLink AboutC2019-570 - 10/17/2019 - NA s � TASK ORDER NO. 3 This Task Order pertains to a Master Services Agreement for Professional Services by and between City of Corpus Christi, Texas(City)and Bath Engineering, (Consultant)dated October 19, 2018(Agreement). Consultant shall perform services on the project described below as provided in this Task Order and in the Agreement. This Task Order shall not be binding until it has been properly signed by both parties. Upon execution, this Task Order shall supplement the Agreement as it pertains to the project described below. PROJECT: E15160 O.N. Stevens Water Treatment Plant Electrical Distribution Improvements 1. PROJECT DESCRIPTION: O.N. Stevens Water Treatment Plant Electrical Distribution Improvements 2. SCOPE OF SERVICES: The scope of services is more fully described in Exhibit A. 3. COMPENSATION —The total amount not to exceed for Task Order No. 3 only is $256,273.00. 4. PROJECT DELIVERABLE(S) TIMELINE: Deliverables will be within 6 months. This Task Order is appro -d, and Consu .nt may proceed. All other terms and conditions of the Agreement remain in full for e an• - ct. • �RP -ISTI BAT eNGINEE� � 411111 /1 ? 1 G/ '' 10/02/2019 moi, eff H. Edmonds, P.E. D. e vVilliam B. :tark, P.E, President Date Director of Engineering Services 5656 South Staples Street, Suite 110 Corpus Christi, TX 78411 (361) 992-2284 Office bstark@bathgroup.com Fund Name Accounting Unit Account No. Activity No. Amount Water 2019 Rev Bond 4098-041 550950 E15160-01-4098-EXP $256,273.00 Task Order No.3 SCANNED TASK ORDER FUNDING REQUEST FORM CONTRACT MSA#AND TITLE:E15160 UNSWTP Electrical Distribution Improvements Rehabilitation FUND NAME/FUND#-ME: ACCOUNT: ACTIVITY: 4098-041 550950 E15160-01-4098-EXP CONSULTANT: Bath Engineering TASK ORDER NO.: 3 SCOPE OF WORK:SEE PROPOSAL TASK ORDER IS FOR PROJECT(S)LISTED BELOW: PROJECT# FEE PROJECT NAME E15160 5256,273 ONSWTP Electrical Distribution Improvements Rehabilitation $256,273 Grand Total LJ Francis, p.6. PM PRI NAME: JI. IG A .' : 10 A DAT'. MSA Beginning Balance: $300,000.00 Task Order#1: $24,000.00 Task Order#2: $10,000.00 Task Order#3: $256,273.00 Remaining Balance: $9,727.00 Task Order No.3 Page 2 of 2 • City of Corpus Christi-PROJECT E15160 R a rh ONS Water Treatment Plant(WTP)Electrical Distribution Improvements Task Authorization No.3--ONSWTP One-lines,SKM,Panel Upgrades VILE Bath Project 3450 Jeff Edmonds P.E. 25 September 2019 City of Corpus Christi Director of Engineering Services Engineering Department 1201 Leopard St. Corpus Christi, TX 78401 Subject: City of Corpus Christi- PROJECT E15160 ONS Water Treatment Plant (WTP) Electrical Distribution Improvements Task Authorization No.3 -- ONSWTP One-lines, SKM, Panel Upgrades Dear Mr. Edmonds, Bath Engineering Corporation (BEC) appreciates the opportunity to provide engineering services to the City of Corpus Christi. The attached Task Authorization No 3 identifies BEC's anticipated level of effort for each task. Background Bath Engineering Corporation conducted an Electrical Site Assessment of the ONSWTP and Booster Pump Stations under Project E15160 Task Order No. 1. The assessment identified several opportunities to improve total system electrical reliability, thus improving overall water delivery reliability. The purpose of this Task Authorization No 3 is to address multiple opportunities identified in the assessment report. These opportunities are inter-related and have been grouped as a single task authorization due to their synergies and interdependencies. Task Authorization Estimate For the performance of engineering, design, and management work based on the scope of work, the following estimated amount is on a Time and Materials (T&M) basis: Engineering Services (1,774 Man-hours) $ 256,273 Material $ 0 Total Task Authorization No 3 $ 256,273 The above amount, including all other approved Task Authorizations is within the limits of our approved contract E15160 MSA. Project Schedule The services stated in this Task Authorization shall be completed within 6 months after Notice to Proceed. BEC's staff will be available to begin work 2-4 weeks after receipt of the executed Task Authorization and Notice to Proceed (written or emailed). Sincerely, *1116 / 9-1A William B. Stark P.E. President Bath Engineering Corporation 5656 South Staples St. Suite 110, CC TX 78411 (361) 992-2284 x109 p (361) 728-3070 c BATH ENGINEERING CORPORATION TEXAS FIRM REGISTRATION NO.F-829 5656 S.Staples St,Suite 110 • Corpus Chnsti,Texas 78411 • Phone 361.992.2284 • Fax 361.992.2287 P:\3450\Admin\TA-Task Authonzatlons\E15160 TASK 3\3450 ONSWTP Task No 3 Fee Proposal Letter REV 9 25 2019.docx Exhibit A Page 1 of 3 • a . ! orh City of Corpus Christi- PROJECT E15160 Scope of Professional Services ONS Water Treatment Plant (WTP) Electrical Distribution Improvements Task Authorization No.3 ONSWTP One-lines,SKM, Panel Upgrade Sept.9,2019 Rev.4 BACKGROUND The City of Corpus Christi operates one(1)water treatment plant,O.N.Stevens Water Treatment Plant,which is rated for 161.5 million gallons per day(MGD). This plant is the only water plant supplying the metro area of Corpus Christi,therefore electrical reliability is critical to the mission of delivering water.The plant receives power from the local electrical utility,AEP,at 69KV which is then transformed to 4160V and distributed by plant owned switchgear and cabling. Bath Engineering Corporation conducted an Electrical Site Assessment of the ONSWTP and BPS under Project E15160 Task Order No. 1. The assessment identified several opportunities to improve overall system electrical reliability. PURPOSE The purpose of this Task Authorization NO.3 is to address multiple opportunities identified in the assessment report dated 4/22/2019.These opportunities are inter-related and have been group as a single task authorization due to their synergies and interdependencies. SCOPE OF WORK The following items were identified in the ONSWTP Electrical Site Assessment Project E15160 Task Order No. 1 Report,dated 4-22-2019. These items are being grouped together due to their synergies and interdependences. This Task Authorization No.3,shall as-built all plant one-lines and panelboards,complete SKM Models and Arc Flash Studies for the ONSWTP and five offsite Pump Stations. The project will also provide designs for replacement of obsoleted panel boards at the ONSWTP filter building and chemical building and relocate Sub 6 main feeder to dedicated breakers at PCR#2. The model and drawings will reflect these revisions. Deliverables include: 1) As-Built One-Lines for ONSWTP, Navigation BPS,Staples BPS,Sand Dollar BPS. 2) As-Built Panel Schedules for ONSWTP,Navigation BPS,Staples BPS,Sand Dollar BPS. 3) SKM model and Arc Flash Studies for ONSWTP, Navigation BPS,Staples BPS,Sand Dollar BPS,Mary Rhoads Pipeline Woodsboro and Bloomington. 4) Provide Arc Flash training and documentation upon completion of SKM model. 5) Arc Flash labels for ONSWTP, Navigation BPS,Staples BPS,Sand Dollar BPS. 6) Installation of Arc Flash labels for or ONSWTP, Navigation BPS,Staples BPS,Sand Dollar BPS. 7) Design Engineering, Drawings,and Construction Specifications for relocation of PCR#6 feeders. 8) Design Engineering, Drawings,and Construction Specifications for Panel Replacement at Filter and Chem building. Engineering and Design work will be completed with-in 6 months of notice to proceed. Any construction services required for execution of the designed work will be billed on a Time&Material basis and are not included in this Task Authorization. BATH ENGINEERING CORPORATION -TEXAS FIRM REGISTRATION NO.F-829 5656 S.Staples St.,Suite 110 • Corpus Christi,Texas 78411 • Phone 361/992-2284 • Fax 361/992-2287 P:\3450\Admin\TA-Task Authorizations\TA 3 Onswtp Onelines SKM Panel Upgrade.DOCX 9/8/19 Page 1 of 4 • • .1.111 OUP IL SCHEDULE The services stated in this Task Authorization shall be completed within 6 months after Notice to Proceed. The Engineer will be available to begin work 2 to 4 weeks after receipt of the executed Task Authorization and Notice to Proceed(written or emailed). FEES The Engineering Service Task will be performed on a Time and Material basis. The table is presented as a reference for tasks and the anticipated level of effort for each task,but does not limit funding to each task as presented. 2019-Engr Index Recommendation Description Fee Chemical Replace obsolete breaker panels and Panels boards are obsolete $10,200 Building transformers. Inspect and test wiring. Filter Building Replace obsolete breaker panels and Panels boards are obsolete $10,200 transformers. Inspect and test wiring. HS#2 Replace existing panel board located in Panels boards are obsolete $7,200 the HS-2 building for 480 and 120V distribution PCR#6 PCR#6-Install Feeders on Dedicated PCR#6 is fed from bifurcated connections from PCR#2 $1,200 Breakers at PCR#2 station power breakers All PCRs Create one set of plant One-Lines One-lines are created on a project by project basis;thus, $30,000 hardcopy and CAD files for delivery to no single set of complete and current drawings exist the plant. All PCRs Provide study and inspection No recent study has been completed. $9,500 grounding systems. ALL PCRs Complete system wide SKM Model and OSHA 1910 requirement for safe worker communication $75,000 Arc Flash Study. Update Arc Flash Labels throughout facility. ALL PCRs Create regular update(5-year cycle)to OSHA 1910 requirement for safe worker communication $0 SKM Model and Arc Flash Study within CMMS systems Chemical Station wide One-Line and Panel As-Built Facilities and create MOC drawings $5,000 Building Schedule Update and inclusion into MOC Documents Chemical Building wide SKM model and Arc Flash Perform SKM Model and Arc Flash Study. Establish $8,000 Building study needs to be updated and power request form and procedure for model maintained every 5 years maintenance. Filter Building Station wide One-Line and Panel As-Built Facilities and create MOC drawings $5,000 Schedule Update and inclusion into MOC Documents Filter Building Building wide SKM model and Arc Flash Perform SKM Model and Arc Flash Study. Establish $8,000 study needs to be updated and power request form and procedure for model maintained every 5 years maintenance. Lab Building Station wide One-Line and Panel As-Built Facilities and create MOC drawings $5,000 Schedule Update and inclusion into MOC Documents Lab Building Building wide SKM model and Arc Flash Perform SKM Model and Arc Flash Study. Establish $8,000 study needs to be updated and power request form and procedure for model maintained every 5 years maintenance. BATH ENGINEERING CORPORATION TEXAS FIRM REGISTRATION NO.F-829 5656 S.Staples St,Suite 110 • Corpus Christi,Texas 78411 • Phone 361/992-2284 • Fax 361/992-2287 P.\3450 Admin\TA-Task Authorizations\TA 3 Onswtp Onelines SKM Panel Upgrade.DOCX 9/8/19 Page 2 of 4 !!afli 2019-Engr Index Recommendation Description Fee Nay.BPS Station wide One-Line and Panel As-Built Facilities and create MOC drawings $5,000 Schedule Update and inclusion into MOC Documents Nay.BPS Station wide SKM model and Arc Flash Perform SKM Model and Arc Flash Study. Establish $8,000 study needs to be updated and power request form and procedure for model maintained every 5 years maintenance. Staples St.BPS Station wide One-Line Update and As-Built Facilities and create MOC drawings $5,000 inclusion into MOC Documents Staples St.BPS Station wide SKM model and Arc Flash Perform SKM Model and Arc Flash Study. Establish $8,000 study needs to be updated and power request form and procedure for model maintained every 5 years maintenance. Mary Rhodes Station wide SKM model and Arc Flash Perform SKM Model and Arc Flash Study The study will $24,000 Pipeline's study needs to be updated and include short circuit modeling and a brief report Woodsboro maintained every 5 years. conveying the short circuit levels. The study will include Pump Station coordination modeling and report on the existing conditions with recommendations for future work to rectify any coordination issues discovered. Includes two trips to station,one for data collection,one for installation of Arc Flash Labels. Includes sketch of Arc Flash zones and recommendation for Arc Flash reduction measures. Work will meet requirement of Rene Marroquin Jr.,Mary Rhodes Pipeline Supervisor, 8/23/2019 Scope of Work. Mary Rhodes Station wide SKM model and Arc Flash Perform SKM Model and Arc Flash Study The study will $24,000 Pipeline's study needs to be updated and include short circuit modeling and a brief report Bloomington maintained every 5 years conveying the short circuit levels. The study will include Pump Station coordination modeling and report on the existing conditions with recommendations for future work to rectify any coordination issues discovered. Includes two trips to station,one for data collection,one for installation of Arc Flash Labels. Includes sketch of Arc Flash zones and recommendation for Arc Flash reduction measures. Work will meet requirement of Rene Marroquin Jr.,Mary Rhodes Pipeline Supervisor, 8/23/2019 Scope of Work. Totals $256,300 The consultant shall not exceed authorized amount without explicit written authorization from the City A/E Contract Administrator(Engineering Services). If you have any questions or if you would like to discuss in more detail,please feel free to call me at(361)992- 2284. Sincerely, ; 41, illiam B.St rk,P.E. President and Principal Engineer Bath Engineering Corporation (361)992-2284 direct (361)728-3070 cell Attachment: Rate Sheet—2018-2021 -EXHIBIT A BATH ENGINEERING CORPORATION - TEXAS FIRM REGISTRATION NO.F-829 5656 S.Staples St.,Suite 110 • Corpus Christi,Texas 78411 • Phone 361/992-2284 • Fax 361/992-2287 P:\3450\Admin\TA-Task Authorizations\TA 3 Onswtp Onelines SKM Panel Upgrade.DOCX 9/8/19 Page 3 of 4 R � ILh MCIEWIZIEMEMII Client: City of Corpus Christi Project Type: ENGINEERING Pro ect Title: ONS Water Treatment Plant(WTP)Electrical Distribution Improvements--Task Authorization No 3 Proposal Request No.: 001 Location: Corpus Christi,TX Proposal Date:24-Sep-2019 BATH Project No.: 3450 Proposal is valid for 90 days City of CC Project No.: E15160 Bath Project Engineer: William B.Stark,PE Client Contact: Larijai Francis Bath Protect Manager: Charles Cofer 1 i I Revision No.: I Principal i Sr Project Sr Engineer, Engineer,PEI Sr Designer •: Designer II Item Total !Engineer,PEI Mgr PE Man-Hour Rate $ 180 $ 169 $ 170 $ 159 $ 128 $ 118 Total Estimated Man-hours 76 77 526 0 1,095 0 1,774 ESTIMATE Estimated Costs $ 13,680 I $ 13,013 I $ 89,420 I $ -I $ 140,160 I $ - $ 256,273 SUMMARY Expenses $0 Total $ 256,273 The purpose of this Task Authorization No 3 is to address multiple opportunities identified in the assessment Project Scope report dated 4/22/2019.These opportunities are inter-related and have been group as a single task authorization due to their synergies and interdependencies Assumptions The estimated cost is provided as a time and materials pricing. Only work and expenses spent will be billed and any additional Clarifications work beyond the scope will be billed as described by the estimate rate schedule above. Bath will make every effort to complete the defined scope of work in less time than has been estimated,but additional or fewer hours maybe required. • Expenses Pnnppal Sr Project TASK DESCRIPTION Engineer,PE 1 Mgr Sr Engineer,PE Engineer,PE i Sr Designer i Designer II em Total TASK AUTHORIZATION No 3 1 PROJECT ADMINISTRATION 77 77 2 CHEMICAL BLDG Replace obsolete breaker panels and 4 25 82 111 transformers.Inspect and test wiring. 3 FILTER BLDG Replace obsolete breaker panels and 4 25 82 111 transformers.Inspect and test wiring. 4 HS#2 Replace existing panel board located in the HS-2 4 17 33 54 building for 480 and 120V distribution s PCR#6 Install Feeders on Dedicated Breakers at PCR#2 4 4 11 19 s ALL PCRs Create one set of plant One-Lines hardcopy and CAD files for delivery to the plant. 4 60 112 176 7 ALL PCRs Provide study and inspection grounding systems. 4 20 40 64 8 ALL PCRs Complete system wide SKM Model and Am Flash Study. Update Arc Flash Labels throughout facility. 4 140 275 419 9 ALL PCRs Create regular update(5-year cycle)to SKM Model and Arc Flash Study within CMMS systems 10 CHEMICAL BLDG Station wide One-Line and Panel Schedule Update and 4 12 23 39 inclusion into MOC Documents 11 CHEMICAL BLDG Building wide SKM model and Am Flash study needs to 4 17 33 54 be updated and maintained every 5 years 12 FILTER BLDG Station wide One-Line and Panel Schedule Update and 4 12 23 39 inclusion into MOC Documents 13 FILTER BLDG Building wide SKM model and Arc Flash study needs to 4 17 33 54 be updated and maintained every 5 years 14 LAB BLDG Station wide One-Line and Panel Schedule Update and 4 12 23 39 inclusion into MOC Documents 15 LAB BLDG Building wide SKM model and Am Flash study needs to 4 17 33 54 be updated and maintained every 5 years Exhibit A 9/25/2019 10:21 AM 1 or 2 Page 2 of 3 3450 MH E, m.r.ONSWTPTASK N.3 9242019..x. RELIOIL1LIZEIEMICIEMIZEI� Client: City of Corpus Christi Project Type: ENGINEERING Pro'ecl Title: ONS Water Treatment Plant(WTP)Electrical Distribution 1 Improvements—Task Authorization No 3 Proposal Request No.: 001 16 NAV.BPS Station wide One-Line and Panel Schedule Update and 4 12 23 39 inclusion into MOC Documents 17 NAV.BPS Station wide SKM model and Arc Flash study needs to 4 17 33 54 be updated and maintained every 5 years 18 STAPLES ST BPS Station wide One-Line Update and inclusion into MOC 4 12 23 39 Documents 19 STAPLES ST BPS Station wide SKM model and Am Flash study needs to 4 17 33 54 be updated and maintained every 5 years MARY RHODES PIPELINE WOODSBORO 20 PUMP STA Station wide SKM model and Am Flash study needs to 4 45 90 139 be updated and maintained every 5 years. 21 MARY RHODES PIPELINE BLOOMINGTON PUMP STA Station wide SKM model and Arc Flash study needs to 4 45 90 139 be updated and maintained every 5 years PROJECT PHASE SUBTOTAL $ - 76 77 526 0 1,095 I 0 1,774 • Expenses Project Mgr II Project Mgr I Engineer IX i Engineer VIII i Advanced Prot Engr Item Total TASK DESCRIPTION Designer V Exhibit A Page 3 of 3 9/25/2019 10:21 AM 2 0,2 3450 MH E 0,m..ONSWTP TASK N.3 9 24 2019..,. EXHIBIT A Iblrh u �■ . ENGINEERING RATE SHEETS ARE CONFIDENTIAL PURSUANT THE SECTION 552.104 OF THE TEXAS GOVERNMENT CODE.SECTION 552.110 OF THE CODE PROTECTS THE RELEASE OF THIS COMMERCIAL AND FINANCIAL INFORMATION RATE SCHEDULE FOR ENGINEERING SERVICES Base Yr. Optional Years Job Classification 10/1/2018 10/1/2019 10/1/2020 10/1/2021 Principal Engineer, PE $175 $180 $185 $190 Sr. Project Manager $165 $169 $174 $179 Project Manager $145 $150 $155 $160 Sr. Engineer PE $165 $170 $180 $185 Engineer PE $155 $159 $163 $167 Jr. Engineer(EIT) $120 $123 $126 $129 - Sr. Substation Specialist $155 $159 $163 $167 Sr. Controls Specialist $150 $154 $158 $162 Sr. Inspector $125 $128 $132 $138 Sr. Designer $120 $128 $132 $138 Designer ll $115 $118 $121 $124 Designer I $95 $97 $99 $101 Administrative Assistant $55 $56 $57 $58 Authorized expenses(lodging, air travel, reproductions, computer charges, etc.) and Subcontractors shall be charged at cost plus 10%. Local travel included in billing rate above. TERMS AND CONDITIONS Charges for services shall be referenced to a project number or purchase order as provided by the Client. Invoices shall be payable to Bath Engineering Corporation in Nueces County, Texas, at 5656 South Staples, Suite 110, Corpus Christi, Texas, 78411. Payment for all charges shall be Net 30 cash. Current: Oct. 1, 2018 Thru. Oct. 1, 2021 BATH ENGINEERING CORPORATION TEXAS FIRM REGISTRATION NO.F-829 5656 S.Staples St.,Suite 110 • Corpus Christi,Texas 78411 • Phone 361/992-2284 • Fax 361/992-2287 P:\3450\Admin\TA-Task Authorizations\TA 3 Onswtp Onelines SKM Panel Upgrade.DOCX 9/8/19 Page 4 of 4 gir°4?). -•-% Arovjytvv. rt Jor 09%1°45 WI 5 4174.11-‘2). Vr#/\ 8/23/2019 �Q/� Rene Marroquin Jr L lfrA Mary Rhodes Pipeline Supervisor General summery for recommended Scope of Work on the Mary Rhodes Pipeline's Bloomington and Woodsboro Intermediate Booster Pump Stations. • Perform Short Circuit Study-A short circuit fault current analysis(three phase bolted fault and single line to ground fault)shall be performed in accordance with ANSI standard C37 and IEEE standard 141 (Red Book)for each bus location that will be receiving and Arc Flash Label. • Perform Device Evaluation Study- Determine whether circuit breakers or fuses have adequate kAIC rating for the available fault current they must withstand.Appropriate multiplying factors based on system X/R rations and protective device rating standards shall be applied.Any problems areas or inadequacies in equipment rating found shall be listed in table format comparing existing kAIC rating to the available fault current. • Coordination Study-A coordination study for devices flagged as nn is-coordinated by SKM software shall be performed in accordance with IEEE 242 (Buff Book)to determine the proper overcurrent device setting that will provided system reliability through selective coordination while minimizing the magnitude of an electrical arc flash hazard incident. Provide time current curves which graphically indicate the coordination of devices.Any devices that are identified as mis-coordinated shall be noted in the study report,and where possible, recommendations shall be made to obtain the required coordination.All setting for relays and circuit breakers or fuse sizes(including manufacture and type)shall be listed in tabular format or on the TCC plot.Any Recommendations givens shall include existing and final setting. • Arc Flash Study-Shall be done for each bus location (calculation point)as identified in the short circuit study. It shall be done in accordance with the applicable standards IEEE 1584-2004a "IEEE Guide for Performing Arc Flash Hazard Calculations" as referenced in NFPA 70E, "Standard for electrical Safety in the Workplace", latest revision, in order to quantify the hazard for selection of personal protective equipment(PPE).Table's that assume fault current levels and clearing time for Proper PPE selection are not acceptable. Pertinent data, rationale employed and assumptions shall be provided with calculations. • Mitigation-provide recommendations ahead of delivering the Study Report that will give the owner a chance to fix problem areas before printing labels.The recommendations shall be broken down into three areas; Arc Flash Analysis:These recommendations shall list all areas where the existing hazards are 8.1 cal/cm2 and higher whether they can be lowered or not,with the goal of mitigating hazards to a lesser incident energy. These recommendations shall include the following: 1. Adjustments to existing current limiting devices(e.g. relays,substation breaker electronic trip settings, molded case breaker instrument adjustment.)the recommendation should include existing and new setting. 2. Replacement of current limiting devices (ex. Fuse replacement) 3. Replacement of obsolete substation breaker(ex. Solenoid style trip units)or molded case breakers 4. Identify where arc flash warning labels shall be affixed.The labels identified shall adhere to ANSI standards and display the flash protection boundary, incident energy,work distance, required PPE level and the shock hazard voltage and boundaries. 5. Recommend the best clothing and PPE options based on the results of the study. �Quscti� r ) ioo NMI ° � r 74/0744r � l lei 'WATER YEARS �. _ .k 1, Y;, ) y 852 E 15160 City of Corpus Christi ONSWTP — PROJECT E15160 Task Authorization No. 1 Cala a "�, .�. 01 ... - ''-'leillii..P.'- .. i, ** . AtItIL eAli I # f n '•' 3 `lo- r' 41 , : , • - ' 4,, jN ,P' •OF T•••4 1 ..- 0)... * '...1.3' -1� * I . * 1 WILLIAM B. STARK / 13 a ir h ,i ,lo 100532 ; tI •. tic ..** •i D,c •. ENS , IlkNA. IIUP IL III IIII SSS/ONAI.ENG\- E N G I N E E R I N G ,...lf.,.-4., William B Stark P.E. Bath Group Inc. — Project 3450 Bath Engineering Corporation Texas Firm Registration NO.F-829 4/22/2019 5656 S Staples Suite 110,Corpus Christi TX 78411 EXECUTIVE SUMMARY: 3 BACKG ROUND: 3 Table 1 Power Sources and Voltages for Major Loads 4 SCOPE. 5 Table 2 Projects Underway 5 Table 3 Temporary Operations/Construction 5 Table 4 Future Facilities/Projects 6 Table 5 Typical Life Expectancy of Electrical Equipment 6 ASSESSMENT: 6 AEP SUBSTATION 6 PCR#1 7 PCR#2 8 PCR#3 8 PCR#4 8 PCR#5 9 PCR#6 9 PCR#7 9 PCR#8 9 PCR#9 10 PRE-SEDIMENTATION AERATION BLOWERS 10 WASH WATER PUMP HOUSE 10 LAB BUILDING 10 CHEMICAL BUILDING 10 FILTER BUILDINGS 10 GAS MEASUREMENT BUILDING 11 STAPLES STREET BOOSTER PUMP STATION 11 NAVIGATION STREET BOOSTER PUMP STATION 11 SAND DOLLAR BOOSTER PUMP STATION 12 NUECES RIVER BOOSTER PUMP STATION 12 RECOMMENDATIONS. 13 Table 6 Recommendations 16 ATTACHMENTS 17 Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 2 • Executive Summary: The electrical and control systems at ONSWTP are generally in very good condition. Upgrades over the past 7 years have replaced a significant amount of the distribution systems. Power Control Room (PCR) #7,8,&9 are new and PCR#1, 2, &3 have had relay upgrades or are in process of relay upgrades. Several projects are underway to improve monitoring(SCADA)of the major substation power systems and establish a backbone to allow extending the monitoring of additional substations. The future projects anticipated over the next 5 years will increase electrical load to the plant by 4 to 6 MVA,almost doubling its current electrical demand. Power is routed to the plant by the local utility company, on wooden poles at 69KV. It is then transformed to 5KV and routed through PCR#1 to the plant. The study identified single point failure concerns in the area of PCR#1, being it is the only source for power throughout the facility. Additional risk exposure lies with the single cable routed in overhead cable tray feeding power to HS#2 and HS#3, the only pumping systems for the plant. The probability of a catastrophic failure of the two single point failures identified is very low, but the consequence is very high, and would result in extended power outages and loss of water production and distribution pumping. To improve the electrical reliability and eliminate the identified single point failures would require installation of a new AEP substation and in-plant distribution sourced from the AEP 138KV lines. This infrastructure would require approximately$8 to$10 million in capital investment but would "harden" the power system with multiple power sources. Other areas of the plant have opportunities for electrical reliability improvement by replacing obsolete equipment;that which is no longer supported by the manufacturers or not repairable because parts are not available. Finally, improvement in the electrical systems documentation and maintenance management systems will aid greatly in improved reliability and efficiency in execution of electrical work. Background: The City of Corpus Christi Texas operates one(1)water treatment plant,O.N.Stevens Water Treatment Plant,which is rated for 161.5 million gallons per day(MGD), with plans to expand to 200 MGD. The plant is the only water plant supplying the metro area of Corpus Christi,therefore electrical reliability is critical to the mission of delivering water and maintaining water distribution quality. The plant receives power from the local electrical utility,AEP, at 69KV which is then transformed to 4160V by AEP owned transformers. The power is then fed to plant owned PCR#1(the Main Substation)switchgear which allows distribution throughout the plant via cabling in underground duct banks,cable trays, and overhead lines to downstream substations, PCR#2 through#9. The power is then distributed to MCCs, panelboards,and other loads via city-owned switchgear,transformers, and cabling. The Northwest side of the plant is supplied by underground power cables in concrete duct banks originating at PCR#1,while the Southeast side of the plant is routed in overhead cable trays. PCR#6 at the filter water recovery pond is fed by overhead CLX cable routed on poles. The following table summarizes the major power sources and voltages for PCRs and other system loads. Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 5 Staples Suite 110,Corpus Christi TX 78411 Page 3 Normal% PCR NUMBER SOURCE VOLTAGE BACK UP POWER Loading/ LOAD SERVED FACILITIES CRITICALITY Capacity AEP STEVENS 69KV 69,000 V 2 Sources 60%with 2 Entire plant Very High SUB Transmission transformers at Line 55°C or 80%with 1 transformer at 65°C rise w/fans 10.5 MVA PCR#1— AEP Stevens Sub. 4160 V 2 Sources with backup 8.6 MVA/ Entire plant Very High ONSWTP generators 1200Amps _ PCR#2— PCR#1—Double 4160 V 2 Sources with backup 8.6 MVA/ HS-1,'A of HS-2 and'A Very High ONSWTP Ended generators.w/process 1200Amps of HS-3,Wash Water redundancy Pumps PCR#3— PCR#1—Double 4160 V 2 Sources with backup 8.6 MVA/ 'A of HS-2 and High ONSWTP Ended generators.w/process 1200Amps '/a of HS-3 redundancy PCR#4— PCR#8 480 V 2 Sources with backup 300Amps Track Vacs. High ONSWTP generators PCR#5— PCR#8 480 V 2 Sources with backup 300 Amps if° Chemical Feed Area High ONSWTP generators source to be installed in near future) PCR#6— PCR#2 4160 V 2 Sources with backup (2)500KVA Wash water pond High ONSWTP generators pumps PCR#7— PCR#1-Double 4160 V 2 Sources with backup (2)750KVA Filter Building Loads High ONSWTP Ended Loop generators w/Loop (Loop to be installed in Configuration near future) PCR#8— PCR#1-Double 4160 V 2 Sources with backup (2)1500KVA Northeast Loads,Sed. High ONSWTP Ended Loop generators w/Loop Loop to be installed in Lift Pumps Configuration near future) PCR#9— PCR#1-Double 4160 V 2 Sources with backup (2)500KVA Northwest Loads High ONSWTP Ended Loop generators w/Loop Loop to be installed in Configuration near future) Chemical Feed PCR#8 480V 2 Sources with Manual 600 Amps IT Servers,Labs, Medium Building Transfer Switch Offices,Warehouse Lab Building PCR#8 480V 2 Sources with Manual 225Amps Lab and Office Medium Transfer Switch Gas PCR#8 480V 2 Sources with Manual 225Amps SCADA Servers on UPS, Medium Measurement Transfer Switch Instrumentation Bldg Filter Bldg PCR#7 480V 2 Sources with Manual Multiple 100 SCADA Servers on UPS, Medium Transfer Switch Amp Panels Instrumentation Generators Fuel 4160V Generators are last 6000MVA PCR#1/Plant wide High resort power source. +200MVA support (future) AEP—Nueces 69KV 69,000 V 2 Sources from AEP (2)4.5MVA Raw Water Pumps Medium River Transmission Line PCR#10— AEP—Nueces 4160 V 2 Sources with backup 600A Raw Water Pumps, Medium Nueces River generators 2000KW Gen. Controls. Staples Street AEP-12,470KV 480 V 1 Source with backup 1500KVA Tank Storage,Booster Medium BPS Distribution generators 450KVW Gen. Pumps,Chem Injection, Controls Navigation AEP-12,470KV 480 V 2 Sources with backup 1500KVA Tank Storage,Booster Medium Street BPS Distribution generators 450KVW Gen. Pumps,Chem Injection, Controls Sand Dollar AEP-12,470KV 480 V 1 Source with backup 1000KVA Tank Storage,Booster Medium BPS Distribution generators 250KVW Gen. Pumps,Chem Injection, Controls Table I Power Sources and Voltages for Major Loads Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 5 Staples Suite 110,Corpus Christi TX 78411 Page 4 • Scope: Bath Engineering was contracted under E15160 Task Authorization No. 1—ONSWTP ELECTRICAL DISTRIBUTION SYSTEMS ASSESSMENT,to provide an assessment of the electrical distribution systems at ONSWTP and its outlying pump and storage facilities at Nueces River, Staples Street, Navigation,and Sand Dollar. The task was to identify potential opportunities to improve the overall electrical reliability of the facilities. Additionally, high level project scopes and estimates would be developed to allow management-level decisions and establish priority for future capital expenditures over the next 3 to 5 years. The study included the power needs of existing facilities, projects underway,and potential projects. The projects considered are listed below along with typical life expectancy of electrical equipment. PROJECTS UNDERWAY PROJECT# TITLE OF PROJECTS STATUS ADDED EST.LOAD UNDER DESIGN OR CONSTRUCTION KVA Access Road Improvements Ongoing 0 Caustic Improvements Ongoing 0 GAC/Nanofiltration Pilot Facility Ongoing Maintenance Building Underway 50 180195 Solids Handling Ongoing 500 18130A Trac-Vac Replacement Ongoing 300 1813A Clearwell 3 Ongoing 0 8605 Permanganate Storage and Feed Ongoing 0 E10144 Chlorine OSG And Handling Facilities Ongoing 2500 E11066 Chlorine Piping Replacement Ongoing 0 E11066 High Service 3/Generator Improvement Ongoing 0 E11068 Nueces Raw Water Pump Station Ongoing 0 E11068 Nueces River Raw Water Ps Transmission Main Ongoing 0 E1221 Raw Water Influent/Chemical Feed Improvements Ongoing 0 E15233 Fluoride Improvements Ongoing 0 E17047 ONS Raw Water Improvements Ongoing 0 Total Added KVA 3350 KVA Table 2 Projects Underway TEMPORARY OPERATIONS/CONSTRUCTION 1 Lagoon 7 Sludge Dewatering and Hauling Operation On AEP Line 2 750 KVA Transformer for Sludge Dewatering Operation On AEP Line Table 3 Temporary Operations/Construction Bath Engineering Corporation Texas Firm Registration NO.F-829 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 5 FUTURE FACILITIES/PROJECTS PROJECT# TITLE OF PROJECTS STATUS ADDED EST. UNDER DESIGN OR CONSTRUCTION LOAD KVA 1 Sedimentation Basin No.5-42 Mg* 300 2 Sedimentation Basin No.6-42 Mg* 300 3 Sludge Dewatering Area* 500 4 Wash Water Recovery Clarifiers-Optional* 5 Clearwell 3 And 4-12.5 Mg Each* 0 6 Filter Building No.3* 500 7 Wash Water Sludge Pump Station* 300 8 Wash Water Sludge Thickening Units* 300 9 Maintenance Building 50 10 Mono-fill Area 21.7 Acres 0 11 Sedimentation Basin Solid Removal Improvements 0 12 Lagoon 8(See Insert) 0 13 Flump and Associated Force Main 300 14 Sodium Permanganate System 0 Future Total Added KVA 2550 Table 4 Future Facilities/Projects TYPICAL LIFE EXPECTANCY OF ELECTRICAL EQUIPMENT TYPE OF GEAR LIFE EXPECTANCY Outdoor Switchgear 40 years 5KV Switchgear 40 years Electronic Power Protection Relays 15 to 20 years Electro-Mechanical Power Protection Relays 40 years 480V Switchgear 40 years Cable—Underground 40 to 50 years Cable—In Cable Tray 40 to 50 years Cable—Overhead Lines 40 to 60 years SCADA Systems 20 to 25 years PLC Systems 20 to 25 years Steel Power Building(Coastal Regions) 50 years Concrete Buildings 50 to 75 years Commercial/Industrial HVAC Systems(Coastal Regions) 10-12 Years Table 5 Typical Life Expectancy of Electrical Equipment Assessment: The electrical and control systems at ONSWTP are generally in very good condition. Recent upgrades over the past 7 years have replaced a significant amount of the distribution systems. PCR#7,8, &9 are new and PCR# 1,2, &3 have had relay upgrades or are in process of relay upgrades. The following is a breakout of each of the major power distribution components within the overall plant system. AEP Substation The AEP substation receives power at 69KV from two sources. Cables to the station are routed on wood poles and looped through the substation. The tie breaker between the two lines is maintained in the Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-11 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 6 OPEN position. If power is lost on one incoming line,the second line will carry the load. The 69KV line is not regulated to the same standard as higher voltages of 138KV and 345KV. The station was originally installed in 1954 with upgrades over the years. Catastrophic failure at this station or the two 69KV lines serving the station would result in loss of utility power. Plant owned backup generators are adequate to carry the entire plant load today and additional generation should be added as plant loading increases. PCR# 1 PCR#1 is the main electrical substation. All power to the facility is routed from AEP through PCR# 1. Additionally,the backup generators are connected to the plant via the switchgear in PCR#1. The existing switchgear is approximately 20 years old with a life expectancy of 40 years. Recent projects have upgraded the protective relaying for the gear. Overall the gear is in good condition. Catastrophic failure at this station would result in loss of all sources of power in the plant. PCR#1 substation building is a single point failure point in the distribution which could result in an extended long-term outage. Failure scenarios include,fire in the building,water damage,or damage due to hurricane or other storms. Although the electrical systems at PCR#1 are redundant and backed up by generators,the equipment is all located in one building,thus failure of the building could interrupt the power sources. PCR#1 building should have a high level of attention and have maintenance conducted regularly to the building and equipment within it. Past upgrades have identified some foreign materials inside the breaker compartments and evidence of rodent presence. The building should be inspected and rodent ingress points closed off. Regular pest inspection and controls should be put into place. The switchgear should be maintained by inspection,cleaning,testing, and calibration at least every 5 years. PCR#1 also houses the generator paralleling gear. This gear was provided by the generator manufacturer and should be inspected and maintained by the OEM at least every 5 years. Components in the paralleling gear are no longer offered in the marketplace but continue to be supported by the OEM at this time with a life expectancy of 10 years. The gear will require an upgrade within the next 10 years. Planning has been completed for power system monitoring PCR#1 via a new SEL RTAC, HMI, and SCADA system integrated with systems from other PCRs and the plant control systems(DCS). This system should be implemented and will act as the HUB for all power monitoring. PCR#1 has three spare breakers for future use, and its bus is rated for up to 2000 amps at 4160V which makes it currently about 50% loaded. Addition of anticipated loads may result in maximizing the bus capacity in an N-1 condition. PCR#1 is connected to PCR#2 and PCR#3 via overhead cable tray supported by substantial steel support structures. All power to the High Service (HS)#2 and#3 is supplied via this single path. Although the structures are not likely to fail in a hurricane or other wind event,the cable tray and cables are exposed to potential damage due to flying debris or heavy equipment such as backhoes or cranes. Damage to the cables would result in loss of pumping at HS#2 and HS#3 which are the only water pumps supplying the City. Possible options to reduce risk of the single point failure would be: 1) Install generation local to HS#3 or#2 for backup power of sufficient capacity for emergencies. Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 7 2) Install a new Substation on the 138KV Transmission Line and distribute power to HS#2&# 3. 3) Install cabling underground to HS#2 and#3, although this does not address the single point failure of the PCR# 1 and AEP Substation. The PCR Air Conditioning systems have recently been replaced and are in good working order. The station has adequate fiber communication. The building and the ancillary equipment are in good condition and meet the load requirements with adequate spare capacity. PCR # 2 PCR#2 provides power distribution for MV motors and their controls at HS#1,#2,and#3. HS#1 is slated for demolition within the next year. These starters are approximately 20 years old and have a life expectancy of 40 years. A project is underway which will upgrade the protective relaying for the starters. Planning is underway to install a power monitoring system at PCR#2 and#3 on the High Service 3 project. The power system will be monitored via a new SEL RTAC, HMI, and SCADA system integrated with the plant PCR#1 and plant control systems (DCS). The PCR Air Conditioning systems have recently been replaced and are in good working order. The station has adequate fiber communication. The building and the ancillary equipment are in good condition and meet the load requirements with adequate spare capacity. PCR # 3 PCR#3 provides power distribution for MV motors and their controls at HS#2,and#3. These starters are approximately 20 years old and have a life expectancy of 40 years. A project is under way which will upgrade the protective relaying for the starters. Planning is underway to install a power monitoring system at PCR#2 and#3 on the High Service 3 project. The power system will be monitored via a new SEL RTAC, HMI, and SCADA system integrated with the plant PCR# 1 and plant control systems (DCS). The PCR Air Conditioning systems have recently been replaced and are in good working order. The building and the ancillary equipment are in good condition and meet the load requirements with adequate spare capacity. PCR # 4 PCR#4 serves the TrackVac and Flockulators systems and houses multiple VFDs with two 480V feeders' sources from PCR#8. This is a special purpose building which is currently in the planning stages to be upgraded or replaced. The PCR Air Conditioning systems are in good working order. The station has adequate fiber communication. The building and the ancillary equipment are in good condition and meet the load requirements with adequate spare capacity. Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 5 Staples Suite 110,Corpus Christi TX 78411 Page 8 PCR # PCR#5 serves the Chemical Storage and Feed area. The station has only one power source connected at this time from PCR#8. Additional MCCs or a Manual Transfer Switch (MTS)are required to make this PCR double ended with two power sources. The PCR Air Conditioning systems have recently been replaced and are in good working order. The station has adequate fiber communication. The building and the ancillary equipment are in good condition and meet the load requirements with adequate spare capacity. PCR # 6 PCR#6 serves the Wash Water Recycle Lagoon#7 area. The primary loads are the Lagoon's water pumps back to the pre-sedimentation pond.The PCR has two transformers which are fed from a bifurcated (shared)feeder off the PCR#2 station power transformers. The feeders to PCR#6 are overhead Metal Clad (MC/CLX)cable strung on wood poles. The station is not critical to operations and can be backed up by a rental generator. Connections for a power generator should be provided at PCR#6. The overhead feeder cable will need to be relocated in the future when Train#3 is installed. The feeder cables should be re-routed and terminated on dedicated breakers at PCR#2 to prevent a fault from dropping station power at PCR#2. The PCR Air Conditioning systems are in good working order.The station has adequate fiber communication.The building and the ancillary equipment are in good condition and meet the load requirements with adequate spare capacity. PCR # 7 PCR#7 is a new building installed in 2012,and serves the filter building,caustic,and fluoride areas of the plant. It is double ended and will be loop fed when PCR#8 and PCR#9 are connected as part of the front-end Raw Water and Chemical Feed Improvement projects.This station also serves the air compressors for the filters backwash. These compressors are fed from starters in PCR#7 but have local interlocked controls which prevent the two systems to operate simultaneously. This may have been due to power restrictions from the past feeder configuration or due to process restrictions. The interlock should be investigated and eliminated if possible.This station is new and modern. This station is new and modern. The PCR Air Conditioning systems are in good working order.The station has adequate fiber communication.The building and the ancillary equipment are in good condition and meet the load requirements with adequate spare capacity. PCR # 8 PCR#8 is a new building installed in 2012,serves the Pre-Sedimentation Low Lift Pumps, Chemical Building, Gas Measurement Building, Lab Building, PCR#4, PCR#5, I/E Shop, Raw water 1-box, Maintenance Shop,and Decant Structure. It is double ended and will be loop fed when PCR#7 and PCR #9 are connected as part of the front-end Raw Water and Chemical Feed Improvement Projects. This station is new and modern. The PCR Air Conditioning systems are in good working order.This station is new and modern. The station has adequate fiber communication.The building and the Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 9 ancillary equipment are in good condition and meet the load requirements with adequate spare capacity. PCR # 9 PCR#9 is a new building installed in 2012,serves the Filter Building, Caustic, and Fluoride areas of the plant. It is double ended and will be loop fed when PCR#7 and PCR#8 are connected as part of the front-end Raw Water and Chemical Feed Improvement projects. This station is new and modern. The PCR Air Conditioning systems are in good working order.The station has adequate fiber communication.The building and the ancillary equipment are in good condition and meet the load requirements with adequate spare capacity. Pre-sedimentation Aeration Blowers The Pre-sedimentation Aeration Blowers' motor starters are located northwest of PCR#9 in an outdoor MCC NEMA 3 enclosure. They are fed from a single source,out of PCR#9. They are not critical to operations. These starters have been subjected to the elements and should be refed from PCR#9 building. Wash Water Pump House The Wash Water Pump House is powered from the HS#2 motor starters. These starters are approximately 20 years old and have a life expectancy of 40 years. Projects underway will upgrade the protective relaying for the starters. The pumps are controlled via a RIO panel located in the building. This RIO panel should be replaced with a dedicated PLC controller. Lab Building The Lab Building is fed from two 225A,480V feeders from PCR#8 via a Manual Transfer Switch (MTS). The lab electrical systems are in fair shape and maintainable. The buildings fluorescent lighting needs to be upgraded to LED throughout. New circuits will be required for anticipated lab benches to be installed in the future. This work will be completed on work orders. Chemical Building The Chemical Building is fed from two 600A,480V feeders from PCR#8 via an MTS. The building 480V electrical systems have been upgraded, but the lower voltage 208/204/120VAC systems are the original installed equipment dating back to 1954. These breaker panels,transformers and wiring are obsolete and beyond service life. Replacement breakers are not readily available in the market and existing units may not operate properly. If the building is to be utilized long term the panels should be replaced and all wiring inspected and tested for service life. The building's fluorescent lighting needs to be upgraded to LED throughout. Filter Buildings The Filter Building is fed from multiple 480V feeders from PCR#7 via cable tray and conduits. The building 480V electrical systems have been upgraded, but the lower voltage 208/204/120VAC systems are the original installed equipment dating back to 1954. These breaker panels,transformers, and wiring are obsolete and beyond service life. Replacement breakers are not readily available in the Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 10 market and existing units may not operate properly. If the building is to be utilized long term the panels should be replaced, and all wiring inspected and tested for service life. The building's fluorescent lighting needs to be upgraded to LED throughout. Gas Measurement Building The Gas Measurement Building is fed from two 225A,480V feeders from PCR#8 via an MTS. The building electrical systems are in fair shape and maintainable. It is anticipated that this building will not be in service after OSG project is installed. Staples Street Booster Pump Station The Staples Street Booster Pump Station (BPS) is fed from a small wood pole mounted 12,470 V overhead line. The line is subject to normal to more than normal distribution level disruptions. The line is terminated at the BPS and then goes underground to an AEP owned, pad mounted transformer. The City takes power at 480V and owns a backup generator. This station was recently upgraded with a new, three-day fuel capacity,whole facility backup generator and automatic transfer switch (ATS). New line feeder cables and motor soft starters were also installed. The controls at this facility are modern after recent upgrades and connected via City owned fiber to the ONSWTP. The communications link does not have a backup or redundancy;therefore,a second pathway should be installed. Facility lighting is obsolete and should be upgraded to LEDs. The pump room ventilation systems are in a state of disrepair and exhibit a high level of corrosion. The systems should be upgraded or replaced in whole. The water lines in the facility are wet with condensation due to the pipeline temperatures which may be corrected with insulation.The gate operator and access controls are not operable and should be repaired or changed to manual. The overall condition of the electrical gear is in good condition and has adequate capacity for the facility. Arc Flash labels are not in place on the electrical gear and need to be installed. Navigation Street Booster Pump Station The Navigation Blvd BPS is fed from two sizable overhead wood pole mounted 12,470 V overhead lines along Navigation Blvd. The line is subject to normal distribution level disruptions with industrial and commercial customers connected to the line. From the overhead lines,two feeders are routed to an AEP owned ATS. This switch faulted over one year ago, has not been replaced or repaired by AEP and a temporary jumper has been installed to restore power. Effectively,the plant currently has only one source of power. The plant has a new,three-day fuel capacity,whole facility backup generator and ATS that reduces the need for two feeders from AEP. AEP should be contacted to replace one of the feeders and remove the ATS. The bill should be credited for the amount of line charges during the time that the service has been single ended and amended for future billing to include only one line. The water lines in the facility are wet with condensation due to the pipeline temperatures which may be corrected with insulation. Facility lighting is obsolete and should be upgraded to LEDs. The gate operator and access controls are not operable and should be repaired or changed to manual. Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 11 • The controls at this facility are modern after recent upgrades and connected via City owned fiber to the ONSWTP. The communications link does not have a backup or redundancy;therefore, a second pathway for communications should be established. The overall condition of the electrical gear is in good condition and has adequate capacity for the facility.Arc Flash labels are not in place on the electrical gear and need to be installed. Sand Dollar Booster Pump Station The Sand Dollar BPS is the oldest of the City owned BPS. It is supplied by AEP on an overhead,wood pole mounted, 12,470 V residential line subject to greater than normal distribution level disruptions due to its proximity to the coast and tree lines. Power is supplied to the first building via an AEP pad mounted transformer which appears to be leaking oil. The second building is fed from the same overhead line but has pole mounted transformers. Arc Flash labels were not in place on the electrical gear and should be installed. The facility and electrical equipment are obsolete and need to be replaced. There are several abandoned and out of service panels and enclosures which should be removed. Plans are underway to upgrade the facility in the near future. Upgrades should include improvements to the site's overall electrical equipment and electrical reliability. AC Unit appears to be obsolete and needs to be replaced. The air handler is making noise,which may indicate impending bearing or belt failure. The site generator has a 400-Gal tank which equates to about 24 hours under load. The general standard today is three-day, run time fuel capacity. Communications to ONSWTP is via City Owned fiber,single pathway. The controls at this facility are modern after recent upgrades and connected via City owned radio link to the ONSWTP. The communications link does not have a backup or redundancy,therefore a second path way for communications is recommended. Nueces River Booster Pump Station The AEP Station is supplied by two 69KV overhead lines with two sets of transformers which have an OPEN tie between them. The station is supplied at 4160V from AEP. Recently,AEP replaced one bank of transformers. City owned electrical power systems at this facility are in the process of being replaced in whole. The new system will have double-ended feeders,automatic transfer capability,whole facility backup generator with three-day fuel storage, and new feeder cables. Additionally, new motor starters and VFDs are to be installed.The facility,after upgrade will be world class with redundant sources and modern PLC controls. Controls will have a second pathway of communication with UPS power.The existing fiber is routed to City Hall IT which has been a reliability issue, but a new dedicated fiber will be routed with the new 54"water line between the plant and the river station. The City Hall IT fiber will become secondary and a backup to the dedicated fiber. The power system will be monitored via a new SEL RTAC, HMI,and SCADA system integrated with the plant PCR#1 and plant control systems (DCS). Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 12 • Recommendations: Recommendations outlined in the above report are summarized in the table below. RECOMMENDATIONS Index Recommendation Description Implement Implementat Priority Notes ation Cost ion Duration All PCRs Create one set of plant One-Lines and One-lines are created on a $30,000 Next 12 High Drawing update required for place under MOC controls. project by project basis;thus,no months SKM and Arc Flash Modeling. single set of complete and current drawings exist All PCRs Provide study and inspection grounding No recent study has been $9,500 Next 12 High Study should consider systems. completed. months lightning protection also. All PCRs Purchase of Small Backup Generator for A 480V generator can provide $50,000 Next 12 Low Can use rental units. 480V Single Ended loads backup generation for unplanned months outages or maintenance activities. All PCRs Secure all PCRs from field mice and other PCR#1,2,3 switchgear should $5,000- Next 12 High Past work on PCR#1 main pests to include regular pest control& have regular inspections. self months breakers identified trash and cleanup of any debris that can be a source perform debris in the switchgear of bedding for pests. ALL PCRs Install Access Control for all PCR Buildings PCR buildings are left unlocked $30,000 6 months Medium Site walk through. Could use and could be accessed by key locks. Access controls can unauthorized personnel. PCR also track operation activities 7,8,9 are key locked. ALL PCRs Complete system wide SKM Model and OSHA 1910 requirement for safe $75,000 6-12 months Medium Past Master Planning and Fee Arc Flash Study. Update Arc Flash Labels worker communication /High Proposal. throughout facility. ALL PCRs Create regular update(5-year cycle)to OSHA 1910 requirement for safe $25,000 5-year cycle Medium Keeps documents and field SKM Model and Arc Flash Study within worker communication labels current. Update re- CMMS systems certifies the site. HS#3 Install generation local to HS#3 or#2 for Install 3 Generators at HS#2 and $3.0 to Next 5 years Medium Consider installing the backup power of enough capacity for #3 4.0MM generator for OSG project at emergencies. HS-3. If this option is chosen,then next two items may not be needed. HS#3 Install underground duct banks from PCR Install UG duct banks $1.2 to$ Next 5 years Medium Solves cable tray damage risk, #2 and/or PCR#3 for motor load 1.5MM but not PCR#1 single source feeders and controls risk. HS#3 Install a new Substation on the 138KV Install new primary Substation $5.0- Next 5 years Medium Locate on existing 138 KV line Transmission Line and distribute power to PCR. $8.OMM at NW 05G. AEP may provide HS#2&#3. some contribution to construction. If this option is chosen,then above two items moy not be needed. Wash Upgrade Control Systems RIO to PLC Rack $75,000 Next 24 Medium Water months PCR#5 Install second feeder to PCR#5 to make it Install new MTS and MCCs. $15,000 Next 24 Medium Work could be completed on double ended. months Raw Water/Chem Feed project. PCR#6 PCR#6—Install Feeders on Dedicated PCR#6 is fed from bifurcated $10,000 Next 24 Low Breakers at PCR#2 connections from PCR#2 station months power breakers PCR#7 Revise controls at Filter Building Air Investigate reason for system $10,000 3 months Medium May allow for more Blowers interlocks and eliminate if operational flexibility and possible faster back washing processes. Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 13 RECOMMENDATIONS Index Recommendation Description Implement Implementat Priority Notes ation Cost ion Duration PCR#9 Relocated the motor starters and controls $75,000 1 Year Low Current starters are exposed from the Pre-Sedimentation Aerators to to the elements and in a state PCR#9 of disrepair. Could be completed on Raw Water/Chem Feed Project PCR#1 Install hardware and integration of SCADA Power Systems Monitoring. $75,000 6 months Medium Past Master Planning and Fee Head End Equipment at PCR#1 to create Proposal. HUB for power monitoring. HS#2 Existing panel board located in the HS-2 $60,000 2 years Low Equipment has been exposed building for 480 and 120V distribution to moisture and should be should be replaced. NEMA 3R at a minimum. Plant Implement MOC policies for document See Attachment 1 $5,000 1 year Medium Report—City of Corpus Christi Wide controls Training/QA QC program. Water Plant—Project E 17093 Electrical Engineering Technical Support Task Authorization No.2— Attachment 1 Plant Implement As-Built—Drawing Files See Attachment 1 $25,000 1 year Medium Report—City of Corpus Christi Wide recommendations Water Plant—Project E 17093 Electrical Engineering Technical Support Task Authorization No.2Attachment 1 Plant Implement CMMS recommendations See Attachment 1 $25,000 1 year Medium Report—City of Corpus Christi Wide Water Plant—Project E 17093 Electrical Engineering Technical Support Task Authorization No.2 Attachment 1 Plant Implement Critical Instrumentation/ See Attachment 1 $25,000 1 year Medium Report—City of Corpus Christi Wide Equipment Identification Water Plant—Project E 17093 recommendations. Electrical Engineering Technical Support Task Authorization No.2 Attachment 1 Plant Restore Standby Generators to load shed Existing standby generator $500,000 Next 12-24 Quote by Vendors Wide program doesn't meet EPA/ERCOT months requirements for load shed program. Revenue generated from the program is no longer available. Plant Implement Plant Wide Power System There is currently no remote $150,000 Next 12-24 Proposals from Bath Wide SCADA monitoring of the power systems months Engineering. Plant Implement regular and complete NETA PCR#1,2,3 switchgear should $75,000/5 Next 12 High 2018 inspection Wide inspection,testing and cleaning of 5KV have regular inspections. years- months switchgear on regular basis. Typically, specialty every 5 years. contractor Plant Implement regular and complete NETA PCR#7,8,9 switchgear should $50,000/5 Next 12 High No inspection conducted Wide inspection,testing and cleaning of 480V have regular inspections. years— months switchgear on regular basis.Typically, specialty every 5 years. contractor Plant Implement regular and complete NETA PCR#4,5,6 should have regular $15,000/5 Next 12 Medium No inspection conducted Wide inspection,testing and cleaning of 480V inspection along with chemical years-self months main distribution breakers on regular building and filter building power perform basis. Typically,every 5 years. systems. Plant Plant wide 5KM model and Arc Flash study Perform 5KM Model and Arc $80,000 6 months Study will provide current Arc Wide needs to be updated and maintained Flash Study. Establish power Flash labels. Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 5 Staples Suite 110,Corpus Christi TX 78411 Page 14 • p . _ RECOMMENDATIONS Index Recommendation Description Implement Implementat Priority Notes ation Cost ion Duration every 5 years request form and procedure for model maintenance. Staples St. Misc.Upgrades for Controls/ Provide second communication $10,000 BPS Communications path Staples St. A/C Ventilation Upgrades Replace systems in pump room. $100,000 BPS Staples St. Lighting upgrades Upgrade to LED $2,000 12 months Low Plant Staff in process of BPS upgrading Staples St. Station wide One-Line Update and As-Built Facilities and create MOC $5,000 6 months Complete task in conjunction BPS inclusion into MOC Documents drawings with Arc Flash Study Staples St. Station wide SKM model and Arc Flash Perform SKM Model and Arc $8,000 6 months Study will provide current Arc BPS study needs to be updated and Flash Study. Establish power Flash labels. maintained every 5 years request form and procedure for model maintenance. Nay.BPS AEP Repairs AEP Repairs $0,000 Coordinate with AEP Nay.BPS Misc.Upgrades for Controls/ Provide second communication $10,000 IT staff in progress of project Communications path development Nay.BPS A/C Ventilation Upgrades Split systems leaking water into $5,000 electrical room. Nay.BPS Lighting upgrades Upgrade to LED $2,000 12 months Low Plant Staff in process of upgrading Nay.BPS Station wide One-Line and Panel Schedule As-Built Facilities and create MOC $5,000 6 months Medium Complete task in conjunction Update and inclusion into MOC drawings with Arc Flash Study Documents Nay.BPS Station wide SKM model and Arc Flash Perform SKM Model and Arc $8,000 6 months Medium Study will provide current Arc study needs to be updated and Flash Study. Establish power Flash labels. maintained every 5 years request form and procedure for model maintenance. Sand Misc.Upgrades for Controls/ Provide second communication $10,000 24 months Anticipated/Project Dollar Communications path underway. Sand Lighting upgrades Upgrade to LED $2,000 24 months Low Complete task in conjunction Dollar with project underway. Sand A/C Ventilation Upgrades Replace system with upgrades Include in 24 months Anticipated/Project Dollar Upgrades underway. Sand Upgrade Sand Dollar BPS Electrical Remove obsolete panel and gear Include in 24 months Anticipated/Project Dollar Systems when facility process upgrades Upgrades underway. are made Sand Upgrade Sand Dollar BPS Generator Increase size of generator and $400,000 24 months Anticipated/Project Dollar fuel storage. underway. Sand Station wide One-Line and Panel Schedule As-Built Facilities and create MOC $5,000 24 months Complete task in conjunction Dollar Update and inclusion into MOC drawings with Arc Flash Study and Documents Station Upgrade Sand Station wide SKM model and Arc Flash Perform SKM Model and Arc $8,000 24 months Study will provide current Arc Dollar study needs to be updated and Flash Study. Establish power Flash labels. Complete task in maintained every 5 years request form and procedure for conjunction with Arc Flash model maintenance. Study and Station Upgrade Lab Station wide One-Line and Panel Schedule As-Built Facilities and create MOC $5,000 6 months Complete task in conjunction Building Update and inclusion into MOC drawings with Arc Flash Study and Documents Station Upgrade Lab Building wide SKM model and Arc Flash Perform SKM Model and Arc $8,000 6 months Study will provide current Arc Building study needs to be updated and Flash Study. Establish power Flash labels. maintained every 5 years request form and procedure for model maintenance. Filter Replace obsolete breaker panels and Panels boards are obsolete $85,000 18 Months Building transformers. Inspect and test wiring. Filter Station wide One-Line and Panel Schedule As-Built Facilities and create MOC $5,000 6 months Medium Complete task in conjunction Building Update and inclusion into MOC drawings with Arc Flash Study and Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 15 4 RECOMMENDATIONS Index Recommendation Description Implement Implemental Priority Notes ation Cost ion Duration Documents Station Upgrade Filter Building wide SKM model and Arc Flash Perform SKM Model and Arc $8,000 6 months Medium Study will provide current Arc Building study needs to be updated and Flash Study. Establish power Flash labels. maintained every 5 years request form and procedure for model maintenance. Chemical Replace obsolete breaker panels and Panels boards are obsolete $85,000 18 Months Medium Building transformers. Inspect and test wiring. Chemical Station wide One-Line and Panel Schedule As-Built Facilities and create MOC $5,000 6 months Medium Complete task in conjunction Building Update and inclusion into MOC drawings with Arc Flash Study and Documents Station Upgrade Chemical Building wide SKM model and Arc Flash Perform SKM Model and Arc $8,000 6 months Medium Study will provide current Arc Building study needs to be updated and Flash Study. Establish power Flash labels. maintained every 5 years request form and procedure for model maintenance. Table 6 Recommendations Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 S Staples Suite 110,Corpus Christi TX 78411 Page 16 . Attachments 1. E17093, Electrical Engineering Technical Support Task Authorization No.3, "Water Plant Maintenance Department Documentation Assessment", William B. Stark P.E.,2019 2. "ONSWTP Plant Facilities Optimization Plan",William Logan Burton P.E. 2017 3. "Plant Electrical Block Diagram", Bath Engineering Corp,William B.Stark P.E.2019 Contributors: Ken Knight,Alex Barabanov P.E.,James Worley, David Cash P.E.,James Hillegeist,Jon Carver. E17093 -Sealed Report ONSWTP EE, ONSWTP Facilities Opimization Plan 34 PDF ca SK-3450-O NSWTP Power Block Diagari Bath Engineering Corporation Texas Firm Registration NO.F-829 Project#3450-T1 5656 5 Staples Suite 110,Corpus Christi TX 78411 Page 17