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Home My WebLink About8A, Lift Station Updates - Modifications�� RU�EN�HILLS Request for Council Action Prepared By: Terry Maurer, Public Works Director Council Meeting Date: January 30, 2012 Lift Station Updates - Modifications Budgeted Amount: Actual Amount: Funding Source: 0 $243,500 Sanitary Sewer Utility Fund Recommendation: Staff recommends Council discuss the proposed upgrades to the City's lift stations and authorize some, or all, of the upgrades to proceed based on the quote from Electric Pump Company. Supporting Documents: l. Memorandum dated January 30, 2012, from Terry Maurer, Public Works Director. 2. Page 62 of the 2011-2015 Capital Improvement Plan (CIP). 3. Page 49 of the 2012-2016 Capital Improvement Plan (CIP). 4. Page 51 of the 2012-2016 Capital Improvement Plan (CIP). 5. Proposals from Electric Pump for lift station improvements. � EN HILLS MEMORANDUM DATE: TO: FROM: SUBJECT: January 30, 2012 Honorable Mayor and City Councilmembers Patrick Klaers, City Administrator � Terry Maurer, Pubhc Works Directo� � � Lift Station Updates - Modifications Background During my short tenure with the City there have been several opportunities to discuss the situation with our 14 lift stations. The lack of any standardization makes the operation and maintenance of the lift stations much more difficult than it should be. Specifically, some of the things I have discovered include: • At least four or five different pump manufacturers are used in the 141ift stations. • One of the prominent pumps present in our lift stations, Pump X, ceased manufacturing in 2005 and discontinued the manufacture of spare parts in 2010. • The operating system used in our most recently reconstructed lift stations, Sycom, is proprietary software and the one vendor that services it has become very unreliable. • Electro Watchman, who we use for monitoring alarms at our lift stations, is not able to provide basic information about alarms. For instance, when Lift Station #8 was overwhelmed by rain water in July 2011, Electro Watchman sent many messages to our Public Works crew about alarms. However, when we were working with the LMC insurance adjuster, we discovered that Electro Watchman could not tell us if Lift Station #8 ever lost power. They could only tell us that there were alarms at specific times, not what the alarm was indicating. Because of the issue of non-standardization, we had Seth Peterson of Bolton and Menk work with our Public Works crew to come up with a standard design, pump manufacturer, and standard control system for all our lift stations that would then become the model for the design of the reconstruction of LS #13. This process took several months and even included site visits by some of our Public Works crew to two service departments of pump manufacturers to review their pumps and see their service departments. After this process we established Flygt pumps as the standard for all our lift stations. City Council Meeting C:\Users\sonj a.klingberg�Desktop\1-30-12LiftStationUpdate.doc Page 1 of 3 We currently have four existing lift stations that are in need of some upgrading. These four lift stations in priority of need for upgrading are: 1. Lift Station #8located at 1335 Ingerson Road. The issues with LS #8 include: • LS #8 has three Pump X pumps; one has failed and was deemed too expensive to repair so there currently is a loaner pump in its place. • The control system is run by Sycom software. • In 2010 a generator was permanently placed on site but has to be manually started in the case of a power failure because the control panel is not equipped to use an Automatic Transfer Switch (ATF) which will automatically start the generator when power fails. This is one of the two lift stations that have the problem of the pumps tipping over during start up. This problem has been diagnosed as being caused by the base elbows which need to be replaced. 2. Lift Station #5 located at 3495 Lake Johanna Boulevard. The issues with LS #5 include: • LS #5 also has Pump X pumps and is the second lift station along with LS #8 that has the problem with the pumps tipping over during start up. Again, the problem has been traced to the base elbows which need to be replaced. • LS #5 also has the Sycom operating software but due to some failures of the software is currently only operating on floats to tell the pumps when to start and shut down. The normal operating system is pressure switches with floats as a backup. 3. Lift Station #7 which is located at 3220 Lake Johanna Boulevard (Presbyterian Homes). The issues with LS #7 include: • This lift station was struck by lightning last summer and a portion of the control panel was destroyed. The lift station is currently operating only on floats. The control panel needs to be replaced due to the damage from the lightning strike. • This lift station also had Pump X pumps; but due to failure, that would have been very costly to repair, they were replaced with Flygt pumps about two years ago. • The lightning strike has been turned into our insurance provider. 4. Lift Station #2 located at 1850 County Road E2 (along the trail behind Perry Park). The issues with LS #2 include: • This lift station has Pump X pumps and a Sycom controller. It is also one of our larger capacity lift stations. Also, as part of the standardization of our lift stations an OmniSite unit would be installed in each upgraded control cabinet. The OmniSite is a monitoring system that will replace the need for Electro Watchman at these upgraded control panels. It will also eliminate City Council Meeting C:\Users\sonja.klingberg�Desktop\1-30-12LiftStationUpdate. doc Page 2 of 3 the need for a SCADA system that is in the CIP in 2014. OmniSite uses cellular technology to provide a cell call, text message, and/or e-mail in the case of an alarm at the lift station. Unlike our current monitoring system, it will identify the exact cause of the alarm so the responding Public Works employee knows what to expect before getting there. It will also create a record for future reference. Similar to a SCADA system, any lift station with an OmniSite controller can have its operation monitored from any computer. The only difference between OmniSite and SCADA is you cannot make adjustments to the lift station operation remotely. The cost of installing an OmniSite at a lift station control panel is about $2,000-$3,000 as compared to a SCADA system that is closer to $12,000-$15,000 based on our 141ift stations. The upgrade of these four lift stations was included as add alternates in the bidding process for Lift Station # 13 reconstruction. However, after evaluating the bid results, staff determined that the costs were too high and there was a more cost-effective way to accomplish the upgrades. Staff then contacted Electric Pump Company, the local supplier of Flygt pumps and OmniSite, and asked them to review each of the lift stations and provide the City a quote to accomplish the upgrades. The detailed quote is attached and the cost for each lift station is as follows: Funding Ontions These proposed upgrades at the four lift stations are not programmed in the current CIP. Lift Station #7 needs to be repaired due to a lightning strike. The other three lift station upgrades could be financed using Sanitary Sewer Utility Funds not needed for other projects. First, there is $162,650 remaining from the proposed monies to reconstruct lift station #11 in 2011 that will not be needed for a few years. Second, there is a CIP item in 2012 for $150,000 for access work at LS #7 that is no longer needed as all of these improvements are part of the Presbyterian Homes project (a copy of the CIP sheet is attached). Finally, there is a CIP item in 2014 to install a SCADA system in the amount of $200,000 (a copy of the CIP sheet is attached). With the use of the OmniSite controller at the upgraded lift stations there is no longer a need for the SCADA system. Council Action Repuested The City Council is requested to discuss these proposed upgrades to the City's lift stations and authorize some, or all, of the upgrades to proceed based on the quote from Electric Pump Company. City Council Meeting P:�Admin\Council�Agendas & Packet Information�2012\01-30-12 Reg Mtg�Packet Information\130-12LiftStationUpdatel.doc Page 3 of 3 ��provement Plan .�ty of Ard� �3� Mu�nesota �roject tt IO-Sew-O(13 •�oje�t Name Reconstruct Lift Stations 11 and 13 .�.ype �rt�provemertt Department Sanitary Sewer D��ent Contact Public Works D�rector Usefui Life Utit� Impro�emen[s Priority n�a Category h` ��* �n i'otal Project Cost: $38�,000 _. c_,, i:a �rar.�� ic 25 vears. ,.�`�....r.___ � � Y g P r .... .. .... ,------- — - ?rnject to rep�ace lift statiorts i 1 1861 Hi hwa 96) and i3 {1123 Kartt► Lake Drive . e avera vew pumPs and electrical panels wouid be installed. The new pumps and panels wouid be compatible with the other 141ift stations focated ;hroughout the Ciry. EnQineering/Design alread�• completed, fiotvever, a review shouid be completed to ensure no design mod►fications are needed. Lift Station # t 1 mav be impacted by �e Highway t0/County Rd 96 Jus 't�fication The lift stations are over 40 years oid and in need of replacement_ Expenditures 201 l 2012 2013 2014 2015 "1"ota� t0.000 Planning/Design »�� 375,000 Construciion/Mai�tenance 375,006 385,000 Total 385,000 2011 thru ZQ15 20t1 2012 2013 2014 2015 Total Funding Sources 385,000 Sanitary Sewer Util�ty Fund 385,000 385,000 Total 3s5,000 Budget Impact/Other � 'ump repair costs should decrease as a result of this project. scheduled for 201 l _ Wedrresday. November !0. 2010 Produced Using the Plan-It CaP'�°I P�°nning Software 6 2 Capital Improvement Plan City of Arden Hills, Minnesota Project# 11-Sew-001 Project Name Sanitary Sewer Pipe & Access Road at LS #7 Description This is a placeholder for future work. No specific project has been identified or studied yet. 7ustificarion Pending future expansion of the site by Presbyterian Homes. This project would provide for some type of an access road to Lift Station #7 that would be able to withstand heavy vehicles. Currently our maintenance vehicles need to drive across turf to access the Lift Station, causing large ruts durin wet periods. This is lanned to be aid for throu h develo er reimbursements from Presb erian Homes. 2016 Totat Expenditures 2012 2013 2014 2015 150,000 Construction/Maintenance 150,000 150,000 Total �50,000 2012 2013 2014 2015 2016 Total Funding Sources 150,000 � Donations/Developer Reimburs 150,000 750,000 Total 150,000 2� 12, th�'u 2016 Department Sanitary Sewer Department Contact Public Works Director 'I'ype Improvement Usefut Life Category Utility Improvements Priority n/a Total Project Cost: $150,000 � � Produced Usin.g the Plan-It Capital Planning Sofhvare 49 Thursday, ATovember 17, 20I1 � � � Capital Impravement Plan City of Arden Hills, Minnesota Project # 12-Sew-004 pro�e�rName Install SCADA System Typ¢ Improvement Useful Life Category Utility Improvements Priority n/a Total Project Cost: $200,000 Description Install SCADA (Supervisory o°n atible and ready tolgo fornnstallat on. he SCADA wil lassist stafflmembes by send ng informa on tto the� booster stations are SCADA p City's computer system. A laptop computer will allow staff inembers to momtor the lift stations, booster stations, and water tower from a remo e location. PUSHED SCADA TO 2014 TO MOVE LIFT STATION REPLACEMENT UP TO 2012 (TJM} Justification The SCADA system would cut down on the number of cali outs during non-business hours and eliminate the need to visually check the City's 1 Lift stations and booster stations on a daily basis. This would be free up manpower for other city functions. The new SCADA system woutd allow the Public Works staff to view level readings from a computer. In addition corrections can be made to the Inumps or equipment through the SCADA computer system, thus saving stat� members a trip to the site. Total Expenditures 2012 2013 2014 2015 2016 p00,000 200,000 EquipNehicles/Furnishings 200,000 Total 200,000 Funding Sources Sanitary Sewer Utility Fund Water Utility Funds 200,000 Tota1 200,000 2012 2013 2014 2015 2016 T� 000 175,000 25,000 25,000 Budget ImpacdOther Chis project will provide a savings on labor for public works. It is estimated that this would be four hours on weekends and two hours daily �tonday thru Friday. Since these hours could be used for other purposes, there is no estimated dotlar impact to the budget at this time. Produced Using the Plan-It Capital Planning Softivare 2� 12 thru 2� 16 Department Sanitary Sewer Department Contact Public Works Director 51 Thursday, November 17, 2011 •!. � •�. ELECTR/C PUMP 201 4 Ave. SW PH# (800) 383-7867 New Prague, MN 56071 FAX# (952) 758-7778 01-19-12 Owner : City of Arden Hills Project: Arden Hills, MN / Lift Station Improvements Engineer: Bolton and Menk Regarding the above project, Electric Pump is pleased to submit this proposal for the following equipment. Two (2) Flygt submersible puxnp model NP3127 461 impeller. This pump will deliver appx 970gpm @ 28TDH, at 1755rpm. An air filled l Ohp, 460-volt, 3 phase motor will drive the pump. FLS and 1-50' of power cable included. The impeller will be Class 35B gray cast iron, dynamically balanced throughout. Standard Flygt paint. Accessories: Two (2) 6" Discharge assembly. * SS guide Rail ea�ists in lift station. Not recommended to replace. Two (2) 2" SS upper guide bar bracket Two (2) SS cable holder Two (2) SS Chain assembly for lifting $18,600 One (1) Control Panel- panel will duplicate LS13 in design. $ 28,400 One (1) Lot of Labor to install above pumping equipment. Install includes necessary bypass of pump station to install base elbows and any miscellaneous hardware. $8,500 Total Price: Start-up and Freight are Included $ 55,500 ;;�� Two (2) Flygt submersible pump model NP3153 464 impeller. This pump will deliver appx 660gpm @ 56'TDH, at 1755rpm. An air filled 15hp, 460-volt, 3 phase motor will drive the puxnp. FLS and 1-50' of power cable included. The impeller will be Class 35B gray cast iron, dynamically balanced throughout. Standard Flygt paint. Accessories: Two (2) 4" Discharge assembly (eccentric reducer is by the contractor) * SS guide Rail exists in lift station. Not recommended to replace. �tI � �;� ELEGTRIC PUMP 201 4 Ave. SW PH# (800) 383-7867 New Prague, MN 56071 FAX# (952) 758-7778 Two (2) 2" SS upper guide bar bracket Two (2) SS cable holder Two (2) SS Chain assembly for lifting $26,500 One (1) Control Panel- panel will duplicate LS13 in design. $ 28,900 One (1) Lot of Labor to install above pumping equipment. Install includes necessary bypass of puxnp station to install base elbows and any miscellaneous hardware. $ 8,000 Total Price: $ 63,400 Start-up and Freight are Included Inspection of panel determined that there is insufficient space available for the components specified including a LC150 controller and Omni Site remote cellular device. It is recommended that a replacement panel be provided duplicating LS 13. Additionally, we recommend housing the Muffin Monster controller in the new panel as well. One (1) Control Panel to duplicate LS13 with additional space for the Muffin Monster Controller. The panel should be rated for 230 volt service powering (2) 10 HP Flygt puxnps. Total Price: Freight is Included $ 31,400 Two (3) Flygt submersible pump model NP3153 434 impeller. This pump will deliver appx 1170gpm @ 43'TDH, at 1755rpm. An air iilled 20hp, 460-volt, 3 phase motor will drive the pump. FLS and 1-50' of power cable included. The impeller will be Class 35B gray cast iron, dynamically balanced throughout. Standard Flygt paint. Accessories: Three (3) 6" Discharge assembly �t� f ��i ELECTR/C PUMP 201 4 Ave. SW PH# (800) 383-7867 New Prague, MN 56071 FAX# (952) 758-7778 * e�usting guide rail is galvanized. We have provided in our scope to replace with SS guide rail. Three (3) 2" SS upper guide bar bracket Three (3) SS cable holder Three (3) SS Chain assembly for lifting $42,400 One (1) Control Panel- panel will duplicate LS13 in design. $31,800 One (1) ATS (Automatic Transfer Switch) — Upon inspection of the station we discussed the ability of the station to be remotely started should a loss of power occur at your main lift station. The control panel would be provided with an ATS to allow for that automatic switching without personnel present to minimize downtime. Confirmation of existing gen sets ability to "auto start" would be required. This requires some additional space in the enclosure. For the Owner's benefit, we have shown this as an adder to the base panel. $5000 One (1) Lot of Labor to install above pumping equipment. Install includes necessary bypass of pump station to install base elbows and any miscellaneous hardware. $ 14,000 Total Price (Including Adder for ATS) $ 93,200 Start-up and Freight are Included Note: Hoist, Junction Box, Valves, Gauges, Piping, Electrical install and anything not specifically mentioned in the above quote is not included in our pricing. This quotation is based on our inspection of the station at time of this proposal. This quote includes only material and services listed, and is subject to modification based on changes in the field. `1� � �i � ELECTR/C PUMP 201 4 Ave. SW PH# (800) 383-7867 New Prague, MN 56071 FAX# (952) 758-7778 Safety Grate Access Hatch upgrades Joe, we also discussed providing fall through protection on stations 2,5,7,8. Attached to the email is the top mount access hatch with safety grate specifications. Currently, the State of Minnesota offers matching grants for every dollar spent to provide this type of equipment. Electric Pump has had success assisting Cities in the paperwork process to obtain these grant dollars. Qty( 9) hatches to replace existing access doors with top mount safety grate covers. Installation would be included in the below pricing. Total Price $ 18,500 If you have any questions or concerns, please feel free to call at 1-800-383-7867. Thank you for your consideration. Sincerely, Tim A. Miller Electric Pump 612-803-3885