HomeMy Public PortalAboutExhibit MSD 77H - 12248 Cost EstimateMemorandum
To: Bruce Litzsinger
From: Karen Janson
Date: September 8, 2017
Re: Caulks Creek A Pump Station (P-750) Improvements (12248)
Attached is a preliminary study for the above referenced project. The project is located in an area
north of Wild Horse Creek Road and west of Baxter Road in the City of Chesterfield within the
Caulks Creek Watershed of the Missouri River Service Area. The purpose of the study was to prepare
a preliminary design and cost estimate to repair and upgrade the existing pump station, P-750, and
eliminate one Known SSO.
The preliminary study recommends constructing a pump station and rehabilitating the existing pump
station and appurtenances. The total preliminary estimated project cost for the proposed work is
$21,500,000.
The improvements will benefit approximately 15,500 properties and the construction will affect one
(1) property. It is estimated that 1 easement will be required. Priority points were not calculated for
this preliminary study. When the conceptual scope for the project was developed, the conceptual
project priority, with a B/C Ratio of 24.8, was utilized along with other factors to schedule the project
for the Master Schedule. This is a Tier 1, Category "B" infrastructure project.
Attachments
pc: Brad Nevois
Jim Dunajcik
Bonnie Hubert
Allen Muehlher
Debra Aylsworth
Jerry Keaveny
Rob Daly
Jay Knicker
Michelle Meier
Brittnee Wilson
File — Karen Janson
Memorandum
To: Karen Janson
From: Robert Miller
Date: September 1, 2017
Re: Caulks Creek A Pump Station (P-750) Improvements (12248)
1. Introduction
A preliminary study has been completed for the above referenced project. This project is
located north of Wild Horse Creek Road and west of Baxter Road in the City of
Chesterfield, within the Caulks Creek Watershed of the Missouri River Service Area. The
purpose of this study is to provide a preliminary design and cost estimate to repair and
upgrade the existing pump station, P-750, and eliminate one known SSO.
2. History
The Caulks Creek A Pump Station was designed in 1981 and constructed in 1986 with
project "Caulks Creek Pump Stations Contract Letting No C-820".
In 2012, Homer and Shrifrin, Inc. attempted an inspection of the wet well as a part of
"GSA — Sewer and Process" (10623). Due to safety concerns, they could not enter the
structure. They inspected as much of the wet well as was possible from the surface, and
found that the portions of the wet well that they could inspect were in good condition,
with one exception near a connection point. A copy of the inspection report is included in
the project folder for reference.
In 2014, The Caulks Creek A Pump Station (P-750) (Caulks A) was partially
rehabilitated with project "Infrastructure Repair #087P Caulks Creek "A" (P-750) Phase
V" (93077D) (10655). This upgrade included new pumps, a new control building, a
connection to the new force main, and a bypass pumping portal. The rehabilitation did
not include any work on the wet well. Operations reports that the wet well for this station
is in poor condition.
A new Caulks Creek force main is being constructed in several phases. The original
Caulks Creek force main is 20-inch diameter. The new force main is 30-inch and 36-inch
diameter. Once completed the new force main should increase pumping capacity and
reduce the operating head required at Caulks A. The new force main was connected to
Caulks A in 2014. Two additional phases of construction are necessary to complete the
new force main to L-52. The completion of the new force main is anticipated to occur in
2020. The original force main is scheduled to be slip lined resulting in a reduced diameter
to an approximate inside diameter of 14-inches. The rehabilitated original force main will
1
remain in place and is planned to be used as necessary when maintenance or repairs are
necessary on the new force main.
The Corp of Engineers is planning a flood wall to protect Caulks A. A small section of
sheet piling was installed; the project was then temporarily abandoned. The flood wall
project is still on the Corp or Engineers' list for future consideration, but it is not
currently scheduled. The Consultant should contact Mr. Jim Mills at the Corp of
Engineers for more information and a status update during the design phase of the
project. While the site is partially in the flood plain, Operations does not recall any
flooding issues at the pump station.
3. Origin of Project
The Watershed Team identified a project to replace the Caulks Creek A (P-750) Pump
Station. The conceptual scope was to demolish the existing pump station and build a
new one due to deterioration.
4. Existing Conditions
The pump station is located in a residential area. The road to the pump station is curved
and has steep grades. Operations reported having difficulty accessing the site with large
equipment such as cranes and large boom trucks.
Operations stated that the existing wet well is in dire need of repair. This does not agree
with the 2012 report by Horner and Shrifrin, Inc. However, this project does include
refurbishment of the existing wet well.
5. Hydraulic Analysis
A hydraulic analysis was not completed for this project. The hydraulic models show that
the Caulks A pump station needs to have a firm capacity of approximately 20 MGD to
account for the 10-year peak flow rate. Caulks A receives flow from three sewers. There
is a 16-inch force main from the Spirit 2 Pump Station (P-736) (Spirit 2), the Caulks
Creek Trunk Sewer from the south and the Wild Horse Creek Interceptor from the
northwest. There is currently no storage available at this pump station, so the peek flow
rate must be pumped. Based on site geometry additional onsite storage of significant
volume does not appear to be a viable solution. Offsite storage may be an option, but
there are other complicating factors, including flow from multiple directions and flow
controls.
6. Proposed Solution
The proposed solution is to construct a new pump station adjacent to the existing pump
station and rehabilitate the existing station. The new pump station should have a capacity
of approximately 10 MGD. This is more than adequate to pump dry weather and some
wet weather flows. It is anticipated that this station would have three pumps, two smaller
2
pumps to handle the typical dry weather flows and a larger pump with a variable
frequency drive (VFD) to pump larger flows. The pumps should be chosen emphasizing
efficiency at anticipated normal operating points. When flow exceeds the capacity of this
new station, the flows would be diverted to the existing pump station with a 36-inch
gravity sewer, therefore providing the needed wet weather capacity. Valves should be
installed that would allow flow to be routed to either pump station based on the flow rate,
or maintenance needs. Valves should also be installed to allow either pump station to use
either force main. It is not anticipated that both force mains would be used at the same
time. The new pump station shall be elevated above the 100-year flood elevation.
Once the new pump station is built, flow would be diverted to the new station and the wet
well on the existing pump station will be rehabilitated. Once the concrete is repaired,
along with any reinforcing required, the wet well should be treated with an appropriate
coating to prevent or reduce further hydrogen sulfide attack.
The Operations Department would like to have the existing building replaced. The
existing building has wood shake shingles, and looks like a house. Operations stated the
building may have originally been constructed in this manor to better blend in with the
architecture of the area. This building requires more maintenance than most of the pump
station buildings. Operations would prefer to have a building which is similar to other
pump station buildings. The elevator in the existing building should be upgraded to a
larger elevator if possible to facilitate the movement of parts, as well as people, to the
lower level of the facility.
The preliminary study assumed a trench style pump station. The consultant should
evaluate this option as well as a submersible pump station and a wet well dry well pump
station. The consultant shall consider pump efficiency, construction space available, and
part availability as well as construction cost when determining the type of pump station to
select for the project. The structure at the pump station shall have adequate hatches or
access points to remove the pumps for maintenance and replacement.
Additionally, the consultant should consider bypass pumping at the Caulks "A" and
rehabbing the wet well. There are some additional risks with this solution. If the wet well
is in worse than anticipated condition, the bypass pumping could be operational for an
extended time period. The long term operational costs, as well as capital costs, should be
considered if using this option.
The existing access road to the pump station is in good condition, but its vertical and
horizontal alignment does not allow for easy access of large equipment. The consultant
shall consider access road improvements to the maximum extent practical. The close
proximity of the road to an existing home and a detention pond may make an alternate
alignment difficult.
Flow meters need to be installed on all force mains. All flow meters shall have the ability
to record and display reading in the control building on site. All controls and flow meters
shall be compatible with the Districts SCADA system.
3
The site already has dual power supplies, but it is anticipated that some electrical
improvements may be required. With the dual power supplies, 24 hour storage or back up
power generation in not required.
7. Constructed SSO
There are no known constructed sanitary sewer overflows in the project area. There is
one capacity related known SSO associated with this project located at manhole 17T4-
011 S.
8. Constructability Issues
There are several concerns that will need to be addressed in the design of this project. A
portion of the property is in the flood plain and the floodway. It is anticipated that a flood
plain study will be required for this project.
There are space limitations that will need to be dealt with. The existing pump station
must remain in service while the new smaller pump station is being constructed.
The alignment of the access road may cause the contractor to have difficulty delivering
and placing larger items.
While the wet well of the existing pump station is being rehabilitated, the pump station
will not have firm 10-year capacity. Permission from The Department of Natural
Resources must be obtained if the old pump station will be out of service for an extended
period of time. If permission cannot be obtained, bypass pumping may be required, or the
contractor may be limited to working in dry weather conditions, either of which could
impact project costs.
The existing pre -grinder or "Muffin Monster" at Caulks A is not functioning. The
"Muffin Monster" should be replaced with a Dimminutor or equivalent unit. This should
be done early in the construction process. Once the Dimminutor is in place, the screen
bypass line should be dry. This will allow the contractor to connect to the screen bypass
line to construct the piping to the new pump station.
The existing 16-inch force main delivers flow from Spirit 2 to the Caulks A. "Spirit of St.
Louis Pump Station (P-336) Replacement" (12207) proposes to add storage to Spirit 2. If
the additional storage is available at Spirit 2 prior to the construction of this project, this
storage could be utilized to switch off the pump station long enough to add the new tee
and valves the force main near it current discharge into Caulks "A",
9. Priority Points
This is a Tier 1 project. Priority points were not calculated for this project. When the
conceptual scope for the project was developed, a priority ranking score was calculated
4
based on SSO removals, service requests/ complaint resolution, CMOM and asset
management benefits, and I/I benefits. MSD considered this priority score and other
relevant information, such as relationships between projects and Consent Decree
requirements, to determine logical sequencing and placement of projects into the
schedule. This project has a conceptual priority (B/C Ratio) of 24.8.
Approximately 15,500 properties are estimated to benefit from this project. Construction
will affect approximately 1 property.
10. Summary and Recommendations
The proposed Project consists of:
• Construction of a pump station with an approximate capacity of 10 MGD.
• Rehabilitation of the wet well of the existing pump station.
• Replacement of the elevator at the existing pump station.
• Replacement of the superstructure at the existing pump station.
• Upgrade the road to the pump station as much as possible.
The total estimated cost for this project is $21,500,000. The project requires 1 easement.
It will benefit approximately 15,500 properties and impact 1 property.
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ENGINEER'S COST ESTIMATE
Project: CAULKS CREEK A PUMP STATION (P-750) IMPROVEMENTS
Number: 12248
Est. By: Robert Miller Date: 3/17/2017
Chk. By: Date:
Rev. By: Date:
Item Pay -Item Estimated Unit Unit Price Extended
14 AIR RELEASE VALVE 2 EA 7000 $ 14,000
23 BOTTOM SECT. OF MANHOLE-2T' PIPE - 36" PIPE 3 L 2700 $ 8,100
364 DRIVEWAYS -ASPHALTIC CONCRETE 1050 SY 65 $ 68,250
408 EXCAVATION CLASS "C" 2100 CY 28 $ 58,800
419 FENCE - 72 INCH CHAIN LINK 420 LF 25 $ 10,500
449 FORCE MAIN 24 INCH 35 LF 325 $ 11,375
508 INSTALL EPDXY LINER 100 LF 275 $ 27,500
546 MANHOLE - STANDARD CONSTRUCTION 27 LF 335 $ 9,045
566 MODULAR BLOCK WALL 300 SF 48 $ 14,400
624 PIPE SEWER 36 INCH (SANITARY/COMBINED) 75 LF 235 $ 17,625
665 PUMP STATION SITE WORK 1 LS 250000 $ 250,000
674 REINFORCED CONCRETE CONSTRUCTION 500 CY 900 $ 450,000
808 REPAIR EXISTING WET WELL 325 SY 2000 $ 650,000
809 ELEVATOR IMPROVEMENTS 1 LS 67000 $ 67,000
811 CONTROL PANEL IMPROVEMENTS 1 LS 500000 $ 500,000
812 DIMMINUTOR 2 EA 200000 $ 400,000
816 LOW FLOW PUMP 2 LS 200000 $ 400,000
817 HIGH FLOW PUMP WITH VFD 1 LS 200000 $ 200,000
818 16-INCH VALVE 2 EA 25000 $ 50,000
819 36-INCH VALVE 2 EA 40000 $ 80,000
820 24-INCH VALVE 1 EA 25000 $ 25,000
821 16-INCH X 16-INCH TEE 1 EA 3000 $ 3,000
822 24-INCH X 30-INCH TEE 1 EA 3000 $ 3,000
824 EXPDXY PROTECTION OF WET WELL 325 SY 200 $ 65,000
825 DRESSER 16-INCH 1 LS 1500 $ 1,500
826 DRESSER 24-INCH 2 LS 2500 $ 5,000
827 DRESSER 20-INCH I LS 2000 $ 2,000
828 BACKFLOW VALVE 16-INCH 1 LS 20000 $ 20,000
829 BACKFLOW VALVE 24-INCH 1 LS 25000 $ 25,000
830 BACKFLOW VALVE 36-INCH 1 LS 30000 $ 30,000
831 36-INCH SLUCE GATE r EA 50000 $ 50,000
832 BUILDING FOR NEW PUMP SATION 1000 SF 200 $ 200,000
833 REPLACE EXISTING PUMP STATION BUILDING 1300 SF 200 $ 260,000
834 CRANE 2 EA 30000 $ 60,000
835 FORCE MAIN 16-INCH 10 LF 325 $ 3,250
836 FORCE MAIN 20-INCH 200 LF 325 $ 65,000
837 BACKFLOW VALVE 20-INCH 2 LS 25000 $ 50,000
838 20-INCH VALVE 2 LS 25000 $ 50,000
839 20-INCH X 20-INCH TEE 1 LS 3000 $ 3,000
840 MISC FITTINGS 1 LS 75000 $ 75,000
841 INSTALLATION 1 LS 350000 $ 350,000
842 FLOW METERS W/ VAULTS 3 EA 40000 $ 120,000
843 DIMMINUTOR VAULT 1 EA 30000 $ 30,000
844 FORCE MAIN RELOCATION 200 LF 325 $ 85,000
845 CONTIGENCY TO REPLACE 20 MGD STATION 1 LS 8000000 $ 8,000,000
1029 VALVE JUNCTION BOX 9 EA 2000 $ 18,000
Initial Subtotal: $ 12,865,345
Construction Utility Relocation
Protection and Restoration of Site (15%)
Mobilization (4%)
Construction Contingency/Allowances (25%)
Secondary Subtotal:
MSD Construction Estimate:
$ 250,000
$ 1,929,802
$ 514,614
$ 15,559,761
$ 4,270,239
$ 19,830,000
Stream Mitigation $
Property Rights Acquisition/Buyouts/Railroad License $
Railroad Flagmen and Insurance $
Design Services/Hydraulic Study/Additional Survey $ 1,670,000
Total Preliminary Estimated Cost: $ 21,500,000
FLOOD PLAIN STUDY
SUBTOTAL
CONTINGENCIES
PERCENTAGE OF SUBTOTAL:
TOTAL
CAULKS CREEK A PUMP STATION (P-750) IMPROVEMENTS
MSD PROJECT 12248
ENGINEERING COST BREAKDOWN
MSD CONSTRUCTION ESTIMATE & CONTINGENCIES:
TOTAL FOOTAGE:
EASEMENTS REQUIRED:
WORKING ROOM REQUIRED:
NUMBER OF PARCELS:
LINEAR FEET OF WORKING ROOM/EASEMENTS:
STRIP MAP
COST FROM SURVEY GRAPH: $2,558.46
EASEMENT SEARCH: $250.00
COST PER PARCEL: $250.00
$19,830,000
275
1
1
0
SURVEY
PER CONSTRUCTION COST:
PERCENTAGE: 0.50%
PER PROJECT LENGTH:
COST PER FOOT: $4.50
EASEMENTS AND LEGAL PREPARATION
PER EASEMENT:
COST PER EASEMENT: $1,000.00
PER PROJECT LENGTH:
COST PER ESMT. FOOT: N/A $0.00
GEOTECHNICAL
FEET PER BORING: 250
NORMAL ACCESS:
LENGTH OF NORMAL ACCESS: 0
COST PER BORING: $1,800.00
TUNNELS: 0
DIFFICULT ACCESS:
LENGTH OF DIFFICULT ACCESS: 275
COST PER BORING: $2,000.00
TUNNELS: 0
ENGINEERING
PERCENTAGE OF CONSTRUCTION COST: 4.00%
CONSTRUCTION SERVICES
PERCENTAGE OF CONSTRUCTION COST: 3.00%
OTHER
$25,000
10.00%
$99,150.00
$I,237.50
$1,000.00
$0.00
$0.00
$2,000.00
$2,808
$99,150
$1,000
$2,000
$793,200
$594,900
$25,000
$1,518,058
$151,806
$1,669,864
MSD ENGINEERING, LEGAL, AND ADMINISTRATION
USE: $1,670,000
Date: 9/8/2017
Caulks Creek A Pump Station (P-750) Improvements
Project Schedule
Proiect Name: Caulks Creek A Pump Station (P-750) Improvements
Project Number: 12248
Scope:
Construct a pump station and rehabilitate the existing pump station and appurtenances.
Estimated Proiect Cost: $21,500,000
DESIGN
MONTHS
PRELIMINARY DESIGN
6
PROPOSALIDESIGN CONTRACT
2
DESIGN STUDY/PIRR & STRIP MAPS
6
DESIGN PLANS/SPECIFICATIONS
6
EASEMENT/ROW ACQUISITION
12
CONSTRUCTION
BID/CONSTRUCTION CONTRACT
4
CONSTRUCTION
18
pc: Bruce Litzsinger
Jim Dunajcik
Bonnie Hubert
Allen Muchlher
File
File (Preliminary Book)
Service Area Lead (Meier)
Watershed Lead (Wilson)