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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 MacDonald · 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 Mayor & Council Page 2 - May 14, 2004 P:\CaK(eret Borough\Hayward Ave PS - Evaluation\Phase 16\5 14-04-HPS PHI g Eval Report Final.doc Hatch Mott MacDonald 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 Mayor & Council - Page 3 - May 14, 2004 p:\Carteret Borough\Hayward Ave PS Evaluation\Phase 1B\$ 14-04 HPS PH 1B Eval Report - Final.doc Hatch Mott MacDonald 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). Mayor & Council - Page 4 May 14, 2004 P:\Carteret Borough\Hayward Ave PS Evaluation\Phase lB\5 14-04 HPS-PH lB Eva~ Report FinaLdoc Hatch Mott MacDonald 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 Mayor & Council - Page 5 - May 14, 2004 P:\Carteret Borough\Hayward Ave PS Evaluation\Phase 1B\5 14-04 HPS-PH I B Eval Report Final.doc Hatch Mott MacDonald 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 Mayor & Council - Page 6 - May 14, 2004 P:\Carteret Borough\Hayward Ave PS Evaluation\Phase 1B\5 14 04 HPS-PH 1B Eval Report - FinaLdoc Hatch Mott MacDonald 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. Mayor & Council - Page 7 - May 14, 2004 P:\Carteret Borough~Hayward Ave PS Evaluation\Phase 1B\5-14 04-HPS PHI B Eval Report FinaLdoc Hatch Mott MacDonald 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 Mayor & Council - Page 8 - May 14, 2004 P:\Carteret Borough~Hayward Ave PS Evaluation\Phase I B\5 14 04 HPS-PH 1B [val Report Final.doc Hatch Mott MacDonald 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~'