IRWD Michelson Water Recycling Plant Phase 2 Expansion

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Picture or Color Block

Irvine Ranch Water District’sMichelson Water Recycling PlantPhase 2 Expansion

MBR Overview

Picture or Color BlockASCE Orange County Branch

December 3rd 2015

Potable Water67% Groundwater & 33% Imported Water

Sewage Collection & Treatment35.5 MGD of Title 22 recycled water capacity

Recycled/ Non-potable WaterIrrigation, high-rise building toilet flushing, industrial use

Urban Runoff TreatmentMan-made wetlands to treat dry weather

runoff and first flush

Irvine Ranch Water District



About the Irvine Ranch Water District California Special District governed by a publicly-elected Board

IRWD customer base• Residential population: 390,000• Daytime population: over 500,000• Service connections: 105,688

IRWD service area• 181 square miles (20% of Orange County)• All or part of six cities and unincorporated county

IrvineTustin

Orange

Lake ForestNewport Beach

Costa Mesa

Phase 2 Expansion increased capacity by 10 MGD from 18 MGD to 28 MGD

Existing plant produces approximately 20 MGD of Title 22 recycled water for unrestricted landscape irrigation

Michelson Water Recycling Plant


Floodwall – 200 Year Flood Protection


Alternative 1:Expansion of Existing Biological Treatment and Filters

MWRP Phase 2 Treatment Alternatives


Alternative 2:Parallel Membrane Bioreactor Train

Alternative 1 – Expansion of Existing Biological Treatment and Filters


Existing Activated

Sludge Train

NewActivated

Sludge TrainFLOW

EQUALIZATIONBASIN

ExistingConventional

Filters

Primary Effluent

Add three new aeration basins and four new circular clarifiers Expand filtration

ExpandedConventional

Filters

Disinfection

Alternative 2 – Parallel Membrane Bioreactor Train


Add new 10 MGD membrane bioreactor process Parallel to existing activated sludge train

Existing Activated

Sludge Train

Existing Conventional

Filters Disinfection

Membrane Bioreactor

Primary Effluent

FLOWEQUALIZATION

BASIN

Evaluation and Selection


Non-Economic and Economic Criteria Non-Economico Technical Performanceo Operation and Maintenanceo Integration with Existing and New

Facilitieso Implementation Requirementso Environmental Impacts

Economico Capital and Operation & Maintenance

Costso Life Cycle Cost Analysis

Alternative 1 Evaluation – Expansion of Existing Biological Treatment and Filters


Advantageso Matches current process configuration &

hydraulic profileo Least number of new unit processes

(simplest operation)o Lower construction and operational cost

Disadvantageso Difficult to implement and phase constructiono More residuals for disposalo Less compatible with potential future treatment

requirementso Footprint requirements may impact other facilities

Alternative 2 Evaluation – Parallel Membrane Bioreactor Train


Advantageso Best water qualityo Best ability to comply with future

regulatory changeso Best ability to accommodate

TDS removalo Smaller footprinto Easiest implementation, ability to

phase constructiono Greatest reuse flexibilityo Lower residuals flow

Disadvantageso Higher construction costo Operational complexity associated with

membrane facilityo Potential long-term reliance on single

membrane supplier

Economic Evaluation – Life Cycle Cost


$64.4M$58.6M

2010 2015 2020 2025 2030$0M

$20M

$40M

$60M

$80M

$100M

$120M

$140M

$160M

Year

Cap

ital a

nd O

&M

Cos

ts

Alt. 1 – Expanded Activated Sludge and Conventional Filtration

Alt. 2 - Parallel MBR with Act. Sludge and Conventional Filtration

Construction Cost (typ)

Combined Treatment Systems


Michelson Water Recycling PlantExisting Treatment Process

NORTH IRVINE INTERCEPTOR

SOUTH IRVINE INTERCEPTOR

INFLUENT GRINDERS

PRIMARY SEDIMENTATION

TANKS

FLOW EQUALIZATION BASINS

ACTIVATED SLUDGE BASINS

SECONDARY SEDIMENTATION

TANKS

DUAL MEDIA

FILTERSCHLORINE CONTACT

TANKS

RECYCLED WATER CUSTOMERS

OCSD



Increase capacity to approximately 28 MGD Completed 2015 Expansion included

o New Influent Sewerso New Headworkso Expanded Primary Sedimentation Tankso Expanded Flow Equalization Facilitieso Upgrades to Conventional Activated

Sludge Processo New High Rate Clarifiero New Membrane Bioreactoro New Ultraviolet Disinfection Facilityo Upgrades to Chlorine Contact Basino Expansion of Recycled Water Pump Stationo New Chemical Facilitieso New Electrical Facilities

Phase 2 Expansion

Phase 2 Expansion Overview

`

HEADWORKSNEWPSTs

EXISTINGPSTs

PEPS

MEMBRANE BIOREACTOR

FLOWEQUALIZATION

BASINS

EXISTINGBLOWER

ROOM

HIGH RATECLARIFIER

UV DISINFECTION

SPENT BACKWASH TANK

CHLORINE CONTACT TANK

EFFLUENT PUMPS

NEW TREATMENT FACILITIESMODIFIED EXISTING TREATMENT FACILITIESNEW CHEMICAL FACILITIESNEW ELECTRICAL FACILITIES

SPENT BACKWASH TANK


Michelson Water Recycling PlantPhase 2 Treatment Process

OCSD

NORTH IRVINE INTERCEPTOR

SOUTH IRVINE INTERCEPTOR

HEADWORKS

PRIMARY SEDIMENTATION

TANKS

FLOW EQUALIZATION BASINS

ACTIVATED SLUDGE BASINS

SECONDARY SEDIMENTATION

TANKS

DUAL MEDIA

FILTERS

CHLORINE CONTACT TANKS RW

CUST.

HIGH RATE CLARIFIER

UV DISINFECTIONMEMBRANE BIOREACTOR

PRIMARY EFFLUENT

PUMP STATION

Evaluation and selection of membrane manufacturer

Pre-purchase of membrane equipment Design around GE/Zenon

ZeeWeed 500D WastewaterMembranes

$9M for 10.6 MGD flow or 1,080,000 sq ft of membranes

Membrane Bioreactor Design

Michelson Water Recycling PlantMembrane Bioreactor

FINE SCREENS

BIOLOGICAL REACTORS

MEMBRANE TRAINS

PERMEATE PUMP ROOM

BLOWER ROOM

FINE SCREENS

ANOXIC ZONES DEOXYGENATION ZONES

AEROBIC ZONES

ANOXIC ZONES DEOXYGENATION ZONES

AEROBIC ZONES

REACTOR 7

REACTOR 8

MIX

ED

LIQ

UO

R

PU

MP

STA

TIO

N

RA

S

BO

X MEMBRANE TANKS

PE

RM

EAT

E P

UM

P R

OO

M

BLO

WE

R R

OO

M

DIP TANK

B.P. TANK

RA

S C

HA

NN

EL

Michelson Water Recycling PlantMembrane Bioreactor

FINE SCREENS

BIOLOGICAL REACTORS

MEMBRANE TRAINS

PERMEATE PUMP ROOM

BLOWER ROOM










Maintain existing plant capacity and operation.

Identify hydraulic and electrical tie-ins.

Set limits on shutdown durations. Detailed sequence for establishing

biomass. Detailed functional testing.

Construction Sequencing


Proper storage - conditioned space.

Educate crew on sensitive nature of the membranes.

Membrane Trackingo Serial Numbero Moisture / Temperature historyo Installed locationo Damaged strandso Permeability history

Training during startup. Membrane Tank Access. Bridge Crane Design.

Membrane Handling and Tracking


Create continuous unobstructed path for foam. Avoid traps/dead ends.

Foam removal is continuous. Mixed Liquor internal bypass allows

Mixed Liquor Re-screening.

Foam and Mixed Liquor Management


GE’s standard programming results in a pulsed flow pattern.

Discovered during commissioning. Impacts to downstream processes,

primarily UV disinfection.

Permeate Flow Variation

Permeate Flow Before Reprogramming

Permeate Flow After Reprogramming


Phase 2 Project Cost

MBR Construction $ 36 Million

Other MBR Related (Electrical Bldg) $ 21.5 Million

Other Treatment Processes $ 31 Million

Overall Construction Cost $ 88.5 Million

Change Orders $ 5 Million (5.6%)

Construction Total $ 93.5 Million

Construction Management $ 11.5 Million (12%)

Design $ 13.4 Million (14%)

Other $ 15.3 Million

Project Total $ 133.7 Million


MBR Operation and Maintenance Cost

Electrical Power $ 453/MG

Chemicals $ 3/MG

Operations Labor $ 71/MG

Maintenance (electrical & mechanical) $ 38/MG

Total $ 565/MG


Questions

Gregorio Estrada, P.E.HDR Engineering, Inc.3230 El Camino Real, Suite 200Irvine, California 92602(714) 730-2391 office(714) 292-5494 [email protected]

Steve Malloy, P.E.Irvine Ranch Water District3512 Michelson DriveIrvine, California 92612(949) 453-5695 office(949) 439-1816 [email protected]