HomeMy Public PortalAboutr 04:184No. ~ Date of Adoption .June 3~ 200/4-
AUTHORIZING A PROFESSIONAL SERVICES CONTRACT FOR THE
HAYWARD AVENUE PUMP STATION WITH HATCH MOTT MCDONALD
WHEREAS, the Borough of Carteret is in need of specializing engineering services in
connection with the Hayward Avenue Pump Station; and
WHEREAS, the Borough's consulting engineers, Hatch Mott McDonald posses the
requisite experience and expertise to provide said services; and
WHEREAS, Hatch Mott McDonald has submitted a proposal to provide said services, to
include an evaluation and recommendation for upgrades to the Hayward Avenue Pump
Station, at a total cost not to exceed $58,000, and;
WHEREAS, the Mayor and the Council have reviewed said proposal; and;
WHEREAS, the Chief Financial Officer has certified that funds are or will be available
for said purpose.
NOW, THEREFORE, BE IT RESOLVED by the Mayor and the Council of the
Borough of Carteret, County of Middlesex, State of New Jersey, as follows:
1. The proposal from Hatch Mort McDonald for engineering services related to the
Hayward Avenue Pump Station at a total cost not to exceed $58,000 is hereby
approved;
2. This action is approved as an award of a professional services contract pursuant to
N.J.S.A 40A:l 1-5(1)(a)
3. The copy of this Resolution be forwarded to the Borough's Purchasing
Department and Hatch Mott McDonald.
Adopted this 3~d day of June, 2004
and certified as a tTue copy of the
original on June 4, 2004.
KATHLEEN M. BARNEY, RMC/CMC
Municipal Clerk
RECORD OF COUNCIL VOTE
COUNCILMAN YES NO NV A.B. COUNCILMAN YES NO NV A.B.
KRUM X RIOS ~(
NAPLES X SITARZ X
PARISI X SOSNOWSKI X
X - Indicate Vote AB - Absent NV - Not Voting XOR - Indicates Vote to Overrule Veto Cp
Adopted at a meeting of the Mu.icipal Council ~__/~I~
CLERK ~ ~
Infrastructure and Environment
Hatch Mott 100Willowbrook Road
Freehold, NJ 07728
MacDonald T 732.780.6565 www.hatchmott.com
May 14, 2004
Hon. Daniel J. Reiman and Borough Council
Borough of Carteret
Memorial Municipal Building / ,~:
61 Cooke Avenue
Carteret, New Jersey 07008
RE: Borough of Carteret
Phase IB - Evaluation and Recommendations
Hayward Avenue Pump Station /
Hill District Sanitary Sewer System
HMM Job No. 208462
Dear Mayor & Council:
As requested by the Borough, Hatch Mutt MacDonald (HMM) is pleased to provide this
report summarizing the second and final portion of our evaluation (Phase IB) of the
Hayward Avenue sewage pump station and force main located in the "Hill District". As
you are aware, this evaluation was authorized by the Borough in accordance with the
recommendations in our initial Phase I report dated November 5, 2003, and was a
necessary ~econd step to obtain the additional information to determine the extent of
physical improvements required for the pump station and force main. We have completed
our field investigations, which included testing of the pump station and force main, and
external and internal examination of the force main with the assistance of the Borough's
emergency service contractor, B&W Construction, Inc.
Our findings are presented herein and we have provided recommendations for physical
improvements to the pump station and force main, including estimated project costs and an
approximate implementation schedule.
Existing Pump Station Deficiencies
The primary problem with the Hayward Avenue Pump Station is that it has not pumped at
it's original design capacity of 625 gpm for many years. Pump tests and flow meter data
indicate maximum pumping rates are actually between 400450 gpm. Due to existing
inflow and infiltration (VI) problems in the service area, combined with the high pump rates
historically discharged by Magmder Ink and Dye / Indol Color Co., and due to the reduced
pumping ability, surcharging and overflows have been a frequent problem at the pump
station especially during significant rain events. This problem has existed since the
construction of the pump station in 1994 and is one of the reasons for the NJDEP imposed
sewer connection ban in the Hill District.
Additional problems noted at the pump station, include the following: ~'~'~.~.
Hatch Mott MacDonald
Hatch Mott
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· Corrosive wastewater has resulted in the premature deterioration of pump and
electrical components. In 1999, various pump station components were replaced
with corrosion resistant components under a rehabilitation contract.
- Construction Code violations from the original pump station construction,
especially with regard to the placement of the auxiliary power generator within the
generator building, has prevented the issuance of a Certificate of Occupancy.
· The comminutor (sewage grinder) electric motor frequently fails requiring
continued maintenance.
· The flow meter is located in the wet well, which is classified as a hazardous
location. The meter has historically had accuracy problems and data from the
meter is questionable.
· The activated carbon odor control system is damaged and requires the media
requires replacement. However, the system has been out-of-service for quite some
time and it is questionable whether the odor control system is warranted at this
station.
· The existing pumps are designed by the manufacturer to pump variable flow rates
at constant motor speed based upon depth of water in the wet well. However, our
observations indicate that the pump output does not vary much and as such, is not
performing as originally designed.
Scope of Investigation
The Hayward Avenue Pump Station was designed in 1994 by American Associates, Inc.
with the following design specifications:
· Station design capacity - 0.90 MGD
· Pump capacity - 624gpm @ 40' TDH, 12.2 HP
· Pump Style - Constant speed/Variable Flow (220 - 624 gpm)
However, test results and flow records indicate the current maximum pump rate is
approximately 435 gpm. Our preliminary investigation in November 2003 concluded that
the force main was suspected to be a primary cause for the reduced pump output.
Therefore, focus of this Phase IB investigation was to determine if the force main had
blockages, trapped air or had corroded to the point where it has a reduced carrying capacity.
A. Blockage or Sediment Buildup - A blockage or sediment buildup in the force
main can significantly impact pump station capacity by increasing the friction
loss and/or operating pressure, thus reducing pump output.
B. Trapped Air - Force mains are designed to have a steady incline in grade.
High points in the force main may result in the trapping of air pockets, which
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can reduce the effective pipe diameter. Normally, anticipated high points are
designed to have air release valves to vent trapped air. However, it is possible
that during construction of the force main, unanticipated utility crossings or
other constraints were encountered, which may have resulted in grade
deviations from the original design. Currently, there are no air release valves
on this force main.
C. Corrosion - Based upon the aggressive nature of the wastewater in the
Hayward Avenue Service Area (Magmder and Gateway) the force main may
be deteriorated or badly pitted/corroded, consistent with the severely corroded
pumps and components identified in 1998.
Under Phase lB the following investigations were completed:
· Install new discharge pressure gauges to conduct 'C' (friction
coefficient) testing on the force main.
· Obtain a sample of the force main pipe for physical inspection of the
pipe interior and exterior conditions.
· Internally inspect the force main from the open excavation.
· Review flow projections from industries and coordinate with MCUA
and NJDEP.
· Review operation of existing pumps.
Upon the installation of new discharge pressure gauges, variable flow testing of the
force main was conducted. However, the results of these tests were again inconclusive.
Discharge pressure readings combined with the flow meter readings indicate that the 'C'
value is above 100, which is acceptable for a pipe of this age and material. Based upon
review of internal video of the force main (as discussed below), the 'C' value seems
reasonable. Some scale has built up on the pipe walls and some corrosion has occurred,
however, no major obstructions or blockages or reduction of pipe diameter are evident.
In April 2004, B&W Construction, Inc., the Borough's Emergency Service Contractor,
excavated the force main and removed a 30-inch long pipe section. Evaluation of the pipe
segment revealed a complete deterioration of the pipe's interior protective cement lining.
The pipe interior also has a scale build-up varying from 1/8" to %" thick, which affects the
hydraulic characteristics of the pipe by increasing friction and reducing pump capacity.
However, of most concern is that the interior pipe wall at the bottom of the pipe (six
O'clock position) has experienced significant metal loss. Measurements of the ductile iron
wall thickness show a loss of approximately 60% of the original wall thickness (0.18 inches
vs. 0.42 inches). From the internal closed-circuit TV inspection, the corrosion of the pipe
bottom is evident along the entire length of the force main inspected. This observation
indicates that in 10 years time, a pipeline with an anticipated useful life of approximately
50 years, has decayed to the point of possible failure. This type of pipe degradation is
indicative of the corrosive wastewater experienced at this pump station.
With the removal of the pipe segment by B&W Construction, it was possible to internally
televise approximately 1,035 linear feet of the 1,800 linear foot long force main. The video
inspection revealed a scale build up along the entire pipe circumference for the length
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inspected. It also showed the deterioration of metal at the pipe invert along the entire
length inspected and it located several long sags in the pipe profile. Evaluation of the video
tape did not reveal the presence of any long-term air pockets as the scale coated the entire
pipe circumference. However, due to the sags in the pipeline, air may occasionally collect
at these high points as there are no air release valves.
Additional information regarding the investigation results, including the closed circuit
television inspection report, and photographs of the force main pipe segment sample
showing the loss of pipe wall thickness are appended to this report.
Conclusions, Recommendations and Estimated Construction Costs
Based upon the findings from this Phase lB evaluation, we have concluded the following:
· The force main requires replacement or relining, due to the internal corrosion and
material loss observed (approximately 60 % of the pipe wall thickness).
· The scale build up on the force main walls, although not the primary cause, is a
factor in reduced pumping capacity.
· The pumps, although replaced in 1999, do not achieve the design flow rate of 625
gpm.
· Based upon observations, the installed pumps do not achieve variable flow rate and
thus do not meet the original design intent.
· The apparent cause for early deterioration of pump components and the force main
are the wastewater characteristics, although a chemical analysis of the wastewater
has not been performed by the Borough.
It is recommended that the Borough consider the following improvements as soon as
possible, to avoid a potential force main failure and to restore, or rather, achieve the design
flow rate of 625 gpm:
· Re-line or replace the existing force main.
· Replace the existing pumping system with new suction lift type pumps that will
relocate the pumps and valves to outside the wet well area (Relocate on top of the
existing wet well slab).
· Replace the existing comminutor with a new electric drive comminutor.
· Install a new flow meter outside of the existing wet well.
· Convert the existing wet well which is configured for a Wemco pump (variable
flow constant speed pump) to a standard wet well for a variable speed/variable
flow pump.
· Abandon and remove existing inoperable activated carbon odor scrubber and
utilize floor area in building for new variable frequency drives (VFD's) for the
new pumps.
· Address the existing code violations for the existing generator and other
components (rotate generator, correct HVAC, and relocate electrical
components).
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With these improvements the Borough will eliminate the problems experienced to date with
the existing pump system installed at the Hayward Avenue Pump Station. The Borough
will have a new pump system that will be more accessible and meet current standards in the
industry. Further, other components that are not reliable or have failed would be replaced
and upgraded with newer technology.
It should be noted that these improvements will involve a by-pass pumping operation to
temporarily convey wastewater flow and maintain service while the force main is re-lined
or replaced and the pumping system replaced. This by-pass operation is similar to that
which was successfully utilized in the rehabilitation of the Dorothy Street Pump Station.
The estimated construction cost of the recommended improvements is approximately
$572,000.
(It should be noted that the existing Wemco pumps, which would be removed from the
Hayward Avenue Pump Station, may be used by the Carteret Sewer Department as spare
pumps for the Bergen Street Pump Station which is a very similar design to the Hayward
Avenue Pump Station.)
Phase II - Hayward Avenue Pump Station Upgrades and Force Main Rehabilitation
Based upon the findings from our Phase I and IB evaluations, we recommend lining or
replacement of the force main and improvements to the pump station as discussed in
previous paragraphs. HMM has provided a description of the engineering tasks and
recommended budgets to complete the scope of services for this project as follows:
1. Design Engineering Services
a. HMM will complete a limited field layout survey of the pump station site.
The new field information obtained from the survey will be added to
existing information that we have on file for the facility. The field survey
will also collect information relative to water main valve boxes, sanitary
sewer manholes, gas valve boxes, and other subsurface utilities that are
marked-out by their respective companies, as necessary;
b. Communicate with utility companies to obtain subsurface utility data to
supplement the field survey information;
c. Perform hydraulic calculations for the sizing of the replacement pumping
equipment as necessary for the upgrade;
d. Design and prepare contract drawings for a pump station and force main
upgrades at the Hayward Avenue Pump Station. The pump station will be
upgraded with new pumps and pump drives and electrical equipment as
noted above and will be designed in accordance with current NJDEP
requirements. The pump station and force main design will include site
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plans, force main profiles, mechanical drawings of the pumps and piping
system modifications, and controls and electrical modifications;
e. Preparation of contract specifications, including technical specifications,
proposal items and up-front documentation for public bidding;
f. Prepare a final construction cost estimate for the pump station and force
main upgrades.
We propose to undertake the design phase of this project for a lump sum fee of
$58,000.
2. Permit Preparation
a. HMM will prepare and submit the appropriate NJDEP Permit Application
forms for a Treatment Works Approval Permit for the upgrade of the pump
station and force main replacement. We will prepare the typical
attachments and documentation, as required by the permit application, and
will submit the permit application to the Borough of Carteret and
Middlesex County Utilities Authority (MCUA) for endorsement of the
appropriate forms. The application will then be forwarded to NJDEP for
approval. All permit fees associated with the TWA permit will be paid for
separately by the Borough of Carteret;
b. Based upon the amount of site disturbance that may be required, we will
prepare and submit a Freehold Soil Conservation District, Soil Erosion and
Sediment Control Permit Application for this project. All permit fees
associated with the application should be paid for by the Borough directly
and are not included in our engineering fee.
We propose to undertake the permit phase of this project as outlined in items 2a. and
2b., for a fee not to exceed $5,000 on a reimbursable basis in accordance with our
current hourly rate schedule. The fee will not be exceeded without the Borough's
authorization.
3. Contract Bidding Assistance
During the contract bid period, HMM will print twenty-five (25) sets of final contract
drawings and specifications for the project bidding and contract signing. HMM will
provide the Borough Clerk with the required information for public bid advertisement.
We will distribute contract documents, and respond to prospective bidder questions
concerning the design, up to within five (5) days prior to receipt of bids, and issue up to
two (2) addenda if necessary. Following the receipt and opening of bids, HMM will
review each bid for completeness and accuracy, and provide the Borough with a bid
report with recommendations for award of the contract.
Hatch Mort MacDonald will offer contract bidding assistance on a reimbursable basis,
in accordance with our current hourly rate schedule. The estimated reimbursable
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budget for completing this work is $4,800, which will not be exceeded without the
Borough' s authorization.
4. Engineering Services During Construction
A scope of services and budget will be provided to the Borough for review and
consideration after completion of final design.
Other Recommendations
1. The reduction of Inflow and Infiltration (I/I) is a priority under the Administrative
Consent Order (ACO), which has been entered into with the NJDEP. It is
recommended that the Borough continue to pursue a reduction of 1/I within this
service area. HMM has assisted the Borough with site investigative work, within
the Hill District and we would be pleased to continue to assist the Borough as
necessary.
2. The Borough has incurred considerable costs over the years to address the
problems at the Hayward Avenue Pump Station and will incur future cost for
rehabilitation and repair of damage due to corrosion. The Borough's Ordinance,
Chapter 207, Sewers, establishes the guidelines for use of the Borough's sewer
system and clearly outlines what discharges are permitted into the sewer system.
The Ordinance outlines a procedure (Section 207-3C, 3D, 7B, 10A, 12B, 14A) by
which the Borough could pursue a course of action to identify the source of
corrosive discharge and potentially such monetary compensation for corrective
work (Section 207-18F). The cost to implement the procedure could range widely
($10,000-$25,000) but if successful, may be reimbursable from the industrial sewer
users. Should the Borough desire to pursue this course of action, Hatch Mort
MacDonald will be able to assist using staff members who are experienced in
industrial wastewater and wastewater characterization studies. Upon request we
will provide an estimate of the costs to implement such a program.
3. As discussed with the Borough on several occasion, it has been noted that the
property located between Industrial Road and Beverly Street is pending
development. Although approvals to move forward with this development may be
dependent on the State lifting the current Sewer Connection Ban that has been
imposed on the Hayward Avenue Pump Station service area, unless the proposed
developer is willing and able to construct a pumping system that will by-pass the
Hayward service area. The NJDEP will likely consider lifting the Sewer
Connection Ban upon the successful reduction of inflow and infiltration in the
Hayward Avenue Pump Station Service Area and implementation of upgrades to
the station. Please note that the pump station upgrades referenced herein will
provide the ability to increase the stations capacity with only minor equipment
adjustments (operating speed) and submission of a Treatment Works Approval to
amend the permitted flow rate. Accordingly, if the State lifts the Sewer Connection
Ban it is possible that the upgraded station will be able to accept the anticipated
wastewater flows from the proposed development with minimal modification,
based upon preliminary estimates of number of dwelling units proposed for the site.
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4. Lastly, the Borough should be concerned with the sewers downstream of the
Hayward Avenue Pump Station with regards to the increased flow, which will be
generated from the upgraded Hayward Avenue Pump Station, and also with regards
to proposed future development within the Borough. The Roosevelt Avenue Pump
Station, which receives wastewater from all of the Borough's sewer collection
system, will be receiving significant increase of wastewater flow when each of the
above projects are completed. Discussions with the Carteret Sewer Department
have indicated concern with the Roosevelt Avenue Pump Station's ability to handle
any significant increases in wastewater flow. Accordingly, it is recommended that
the Borough consider an evaluation of the existing Roosevelt Avenue Pump Station
with regards to recommended upgrades and required maintenance.
Engineering Cost Summary
In summary, the following is a list of the estimated professional engineering fees associated
with the design, permitting and bidding of improvements to the pump station and
rehabilitation of the force main as described in the preceding paragraphs:
Phase II - Hayward Avenue Pump Station Upgrades and Force Main Rehabilitation
1. Design Engineering Services (Lump Sum) $58,000
2. Permitting Services (Reimbursable Budget) $ 5,000
3. Contract Bidding Assistance (Reimbursable Budget) $ 4,800
4. Engineering Services During Construction (Reimbursable Budget) Pending
HMM is available to proceed immediately with the scope of services described above. It is
anticipated that a period of six (6) to eight (8) weeks will be required to complete the
design of the pump station upgrades and force main rehabilitation or replacement.
Upon review of this information, please notify HMM on how the Borough wishes to
proceed.
If you have any questions or require additional information concerning the information
provided, please do not hesitate to contact our office.
Very truly yours,
Hatch Mort MacDonald
Eric C. Betz, PE, CME
Associate
T 732.780.6565 F 732.577.0551
eric.betz@ hatchmou.com
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Attachments
cc: Kathleen M. Barney, RMC/CMC
Patrick J. DeBlasio, CFO
Mike Camivale, Jr. Supervisor, Sewer Dept.
Donald Norbut, PE, Carteret Borough Engineer
Albert N. Beninato, PE, PP, DEE
Robert C. Mainberger, PE, CME
Mayor & Council - Page 9 May 14, 2004
p:\Carteret Borough\Hayward Ave PS Evaluation\Phase 18\5-14 04 HPS PH lB Eval Report Final.doc
National water Main Cleaning
875 N. Summer Avenue
INSPECTION REPORT
STREET: HAY~NARD AVE ~ ~ ~D DITCH
MATERIAL~ DUCTILE IRON JT LGTH:
SECTION TYPE: WASTEWATER LINING:
AREA: RSRVD:
1:1525 DIST OBSERVATION VCR# PH RATE
IN FRONT OF 11 HAYWARD AVE
D~ ~ ,nspectionbeg,nsatupstream DITCH 00:00:00 0
j ~ scale,ff'qmeral deposits light from 07 to 05 o ciock 000124 2a
384 61 sag begins
."~-'----~.~401.37 sag ends 00:26:13 0
""'~41071 scale/mineral deposits medium from 07 to 05 o'clock 00:26:39 9a 2
487.11 pipe bends dght 00:29:27 0
~ 507,29 pipe bends left 00:30:20
5;8 57 scale/mineral deposits !igt¢ from 12 to 12 o ciock ~903323 12a
61692 sag begins 003507
~-- 0036 ~6
% 626 26 camera under wate~
BWC001-3.mdb II PAGE: t
National Water Main Cleaning
875 N. Summer Avenue
INSPECTION REPORT
1;t525 DIST OBSERVATION VCR# PH RATE
665.11 sag ends 00:40:43
925 83 sag begins O0 5! 33
DO 939,18 inspection ends at downstream 00:56:31
BWC001-3.mdb // PAGE:2
National ~ Main Cleaning
875 N. Summer Avenue
INSPECTION IMAGES
CITY: STREET: DATE: SECTION NR: SECTION NAME:
C~RTERET, N. ,-
IMAGE: 2a, TAPE #: 1(TV101), 00:01:24
9.54FT, scale/mineral deposits light from 07 to 05 o'clock
IMAGE: 9a, TAPE #: 1(TV101), 00:26:39
410.71FT, scale/mineral deposits medium from 07 to 05 o'clock
BWC00t-3.mdb II PAGE: 3
National Water Main Cleaning
875 N. Summer Avenue
INSPECTION IMAGES
.~ SECTION NR: I SECTION NAME:
IMAGE: 12a, TAPE #: 1(TV101), 00:33:23
578.57FT, scale/mineral deposits light from 12 to 12 o'clock
BWC001~.mdb II PAGE:4
INSPECTION REPORT
:250 DIST OBSERVATION VCR # PH RATE
0.00 inspection begins at downstream DITCH 00:06:26 0
723 scale/milaeral deposits iir]nt from O? to 05 o clock 0,. O, ,z ba
95.98 inspection ends at upstream 90 00:11:56 0
National Water Main Cleaning
875 N. Summ~ Avenue
INSPECTION IMAGES ~
SECTION NAME:
CITY: STREET: SECTION NR: ~
CARTERET, H, J. (.
HAYWhq~ RVE · J"
VlAGE: 5a, TAPE #: 1(TV101), 00:07:12
7.23FT, scale/mineral deposits light from 07 to 05 o'clock
BWC0Ot-3.mdb II PAGE:6
06/08/2004 11:15 FAX 732 541 8925 EORO OF CARTERET CLERK ~001
~ TX REPORT
TRANSMISSION OK
TX/RX NO 2O02
CONNECTION TEL 7325412884
CONNECTION ID
ST. TI~E 06/08 11:15
USAGE T 00'34
PGS. SEI~,~r 1
RESULT OK
~{DDt.,E~EX
TEL (732) 541-3800
FAX (732) 541-8925
~[-~N M- B~WEY. ~M~C~C 61 CO0~ A~E
MUNICIP~ ~g~ ~e: ~e 8. 20~ ~ERET, NEW JERSEY ~008
To: Patrkk~l~io
Bom~h of ~
~Q~ FOR C~TIFI~TION OF A ~ ~DS:
FOR: Ha~ Av~ ~p
NAME OF ,4 CCOUNT: Hatch Mo~t McDonald
AMOUNT TO BE ENCUMBERED: NOT TO EXCEED $58,000.00
KATHLEEN M. BARNEY,
Muuicip,,i Clerk
CERTIFICATION OF AV.41L/IBH. ITY OF FUNDS
I, Treasurer of th~ Borough of Cart~et, do hereby cerafy that there are sufficient funds
available in the current budget to enable the Municipal Council to authorize the entering
into a contract between the borough of Carteret and.'.
The ~untl~ available for this contract are in the_ th~l~e.t in tl~ etft. n~lnt nt~'