Built to Last – Rehabilitating 5 Miles of Sewer Force Main in Newport Beach, CA

87th Annual WEFTEC Conference

September 30, 2014

Dan Bunce, P.E., PMP and Victoria Pilko, PMP

Orange County Sanitation District (OCSD) BackgroundVictoria Pilko, PMP

OrangeCountyOrangeCounty

Ocean Pipeline

Reclamation Plant No. 1

Treatment Plant No. 2

NewportNewportBeachBeach

FountainFountainValleyValley

Santa AnaSanta Ana

Los Los AlamitosAlamitos

Buena Buena ParkPark

FullertonFullerton

TustinTustin

Garden GroveGarden Grove

La HabraLa HabraBreaBrea

PlacentiaPlacentia Yorba LindaYorba Linda

AnaheimAnaheimAnaheimAnaheim

OrangeOrange

La PalmaLa PalmaCypressCypress

WestminsterWestminster

IrvineIrvine

StantonStantonVillaVillaParkPark

CostaCostaMesaMesa

HuntingtonHuntingtonBeachBeach

SealSealBeachBeach

OCSD Service Area572 miles of sewers200 million gallons per day15 pumping stations2 treatment plants

471 square miles

2.6 million population

21 cities

3 special districts

Wastewater Conveyance Summary

• Full secondary treatment was achieved in 2011 Headwork capacity P1 = 280 MGD,

P2 = 317 MGD Outfall pumping capacity (Long

outfall 480 MGD, Short outfall 240 MGD)

• Disinfection of final effluent began in 2002

• 23 megawatts of power generation - enough to power 20,000 houses

• 750 average wet tons of biosolidsare processed per day

OCSDcollects/treats about 198 million gallons of wastewater every day.

The flow received is about 80% municipal and 20% industrial.

Newport Force Main Project BackgroundVictoria Pilko, PMP

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Newport FM is a very Critical Element of the OCSD Collection System

Project ChallengesDan Bunce, P.E., PMP

Holistic Rehabilitation was Needed Consequences of Failure are Too High

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Community Impacts

EnvironmentalImpacts

EconomicImpacts

9

Major Businesses Along the Alignment

Bike Community

10

Vehicle, Bike, and Pedestrian Traffic Needed to be maintained

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Technical Challenges

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Sewer Pressure Cured-in-place-pipe (CIPP ) used for 50% of the Rehabilitation

• Needed to maintain hydraulic capacity

• Full structural solution was required

• Minimize use of corrosive material

• Limited industry experience in Pressure Sewer CIPP Applications

Other Technical Challenges

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Bridge and Deep Storm Drain Crossings required Microtunnel

Hydraulic Constraints

Innovative Solutions NeededDan Bunce, P.E., PMP

Focused Disciplines Needed to Deliver the Innovation• Urban Trench Pipeline Design

• Pressure Sewer Cured-in-Place-Pipe Engineers

• Tunneling Design Engineers

• Geotechnical Engineers

• Groundwater Dewatering Engineers

OCSD called this the “Dream Team”

The Design Team

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Segment Analysis

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Considered Multiple Renewal Solutions

• Trenchless Rehabilitation• Slipline• CIPP

• Tunneling New Pipe• HDD• Microtunnel• Jack & Bore

• Open-cut New

The Innovation Resulted in Key Improvements:• Full Redundant Force Main System

• Public and Worker Safety

• Increased System Reliability

• Reduced Community Impact

• Ease of Maintenance

Built to Last for the Next 50 Years

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#1: Redundancy Built into the System

Step 1:Construct a connection from Lido PS to North Force Main

Step 2:Remove Crossovers and Valves

Step 3:Upsize 4000 ftof South Force Main to eliminate bottleneck

Savings of $2M Net Present value (NPV)

#2: Common Trench Replacement

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• 30 year old HDPE Sliplinedin older VCP Gravity pipe

• Uncertain DR and details on installation

• Pipe was constructed under the sidewalk in front of several businesses and driveways

• Pipe is in close proximity to high pressure gas and water lines

#3: Replacement vs Rehabilitation using Business Case Evaluation

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Existing North Force Main

Alternative 1: Construct a New Pipe in a New Alignment Now

Alternative 2: Defer Construction of New Pipe for 5-10 years

#3: Replacement vs Rehabilitation using Business Case Evaluation

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Approximately $750k in Savings by replacing now Considering Risk Cost

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Consequence of Failure Cost Annualized Risk CostEmergency Response, Isolation and Cleanup

$ 509,600 $ 47,393

Community Disruption $ 100,000 $ 9,300

Potential Fines $ 500,000 $ 46,500

Potential Property Damage/Loss of Business Claims

$ 3,000,000 $ 279,000

Acknowledgements

Additional Core Design Team Members: • Sharon Yin, Project Engineer (OCSD)• Martin Dix, Construction Phase Project Manager (OCSD)• Mark Briggs, Project Design Manager (BC)• Jason Gornall, Senior Pipeline Engineer (BC)• Kelly Derr, CIPP Specialist (BC)• Cherylle Barrido, Specifications and Lead Construction

Support (BC)• Ed Kampbell, CIPP (Jason Consultants)• David Kuan, Traffic Control Engineering, Inc.• Kleinfelder, Geotechnical Engineering• Shannon & Wilson, Groundwater Dewatering Design

Acknowledgements

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Existing North Force Main

Questions ?

Dan Bunce, P.E., PMP and Victoria Pilko, PMP