BEFORE THE ILLINOIS POLLUTION CONTROL BOARD
IN THE MATTER OF:
WATER QUALITY STANDARDS AND
EFFLUENT LIMITATIONS FOR THE
CHICAGO AREA WATERWAY SYSTEM
AND THE LOWER DES PLAINES RIVER:
PROPOSED AMENDMENTS TO 35 Ill.
Adm. Code
Parts 301
,
302, 303 and 304
R08-9
(Rulemaking - Water)
PRE-FILED TESTIMONY OF THOMAS E. KUNETZ. P. E.
Capital Improvements Program
Introduction
My name is Thomas E. Kunetz. I am the Assistant Chief Engineer in charge of the
Process
Facilities
Division of the Engineering Department of the Metropolitan
Water
Reclamation District of Greater Chicago (District). I have been in my current position since
2005, and have been employed in various engineering positions with the District since 1992. 1
hold a BS degree in Environmental Engineering from the Pennsylvania State University, and an
MS degree in Water Resources Engineering from Villanova University. I am a registered
Professional Engineer in the states of Illinois, Pennsylvania, and New Jersey, and have 23 years
of experience in the field of wastewater engineering. In my current position, I am in charge of
the production of contract documents for the upgrade, rehabilitation, and expansion of the
District's seven water reclamation plants and outlying facilities.
The purpose of this testimony is to briefly explain the program through which the District
identifies, plans for, and allocates funds for the capital improvements projects necessary to
repair, rehabilitate, replace, and expand the infrastructure of the District's water reclamation
plants (WRP). The costs that are presented herein represent the baseline financial obligations of
the District that are necessary to keep the water reclamation plants functioning under the current
1
regulatory framework through the
year 2040
planning horizon. Costs for infrastructure that
would be
required
to comply with
new regulatory standards must be recognized to be above and
beyond the
baseline obligations
.
It
should also be understood that the costs presented in this
testimony are for capital projects, and as such
,
are in addition to costs incurred
by the
District on
an annual basis to operate and maintain the water reclamation plants. The costs presented do not
include engineering design fees, outlying District facilities
,
intercepting sewer projects
, or TARP
projects.
Capital Improvements Program
The District owns and operates seven water reclamation plants to serve the greater
Chicago area
.
In order to provide continuous service, maintain water reclamation plant
efficiency,
and ensure that each water reclamation plant meets the requirements of the National
Pollutant Discharge Elimination System
(NPDES)
operating permits and other regulatory
requirements, the infrastructure within the water reclamation plants must be properly maintained.
The District
has a Capital Improvement Program
(CIP) to
identify and implement projects
necessary to meet these needs. Projects are identified for inclusion in the
CIP in
one of two ways:
through recommendations as a result of facility planning studies, or through requests by the
Maintenance and Operations Department
,
based on internal investigations and inspections.
Beginning in the year
2000,
the District initiated the Infrastructure and Process Needs
Feasibility Study process. The purpose of the Infrastructure and Process Needs Feasibility Study
is to identify
,
evaluate and prioritize capital improvements projects necessary to update processes
to current technology
,
to improve treatment efficiency
,
reduce maintenance and operation costs,
and reduce energy consumption at each water reclamation plant while continuing to produce
exceptional quality effluent through the year 2040 planning
horizon. The year
2040 was chosen
as the planning
horizon for
the first three studies, as this year was 40 years into the future when
2
the process started for the first study. One of the significant products of the Infrastructure and
Process Needs Feasibility Study is a Master Plan. The Master Plan is a "road map" to the future,
a plan that identifies and prioritizes the major projects that need to be implemented to achieve the
established goals for the plant through 2040.
The need for these studies was driven by the age of the District's largest facilities. The
Stickney, Calumet, and North Side WRPs are among the very first secondary treatment facilities
in the country. Some of the infrastructure and processes at these plants were constructed in the
1920s and 1930s. Attachment 9 of the pre-filed testimony of Richard Lanyon presents a timeline
depicting the very early commitment of the District to the construction and continuous upgrading
of these water reclamation plants. Currently,
Master Plans have been completed for Stickney,
Calumet and North Side WRPs, while the Infrastructure and Process Needs Feasibility Study has
just started for the Hanover Park WRP.
Objectives of the Infrastructure and Process Needs Feasibility Study
The main objectives of the Infrastructure and Process Needs Feasibility Study are as
follows:
•
Assess Future Flows and Pollutant Loadings
•
Maintain Treatment Capacity through Year 2040
•
Replace/Upgrade Undersized or Underperforming Unit Processes
• Evaluate Opportunities for Process Changes
•
Prepare to Respond to Potential Changes in Regulations
•
Standardization Between Plants Where Practical
The process proceeds in a systematic manner, starting with an initial assessment of the
existing plant to identify areas of concern, focusing on process objectives, and aging
infrastructure. Projections are made for anticipated future flows and loads to the treatment plant.
These are based on population and industrial growth projections to the planning horizon, which
3
was chosen as the year 2040 for these studies. Next, a computer model of the plant is created to
be used as a tool in evaluating current process efficiencies, and the impact of potential future
modifications
.
Each of the process areas of the plant are evaluated on its ability to meet the
demands of the year 2040 projected conditions
.
Recommended solutions are evaluated on a
plant
-
wide basis to determine the impacts of interrelated process areas. Finally, a Master Plan is
developed which establishes a prioritized list of projects which are necessary to implement in
order for the water reclamation plants to continue to produce exceptional quality effluent through
the year 2040 planning horizon.
Stickney WRP Master Plan
The Master Plan for the Stickney Water Reclamation Plant was completed in 2005. The
Master Plan projects for the Stickney WRP are listed in Attachment 1. Significant recommended
projects include:
•
Construction
of new sludge thickening tanks
to take the
place of existing,
undersized
,
overloaded sludge concentration tanks, and replacement of the aging
pre-digestion centrifuges
($173,000,000)
• Elimination
of the
existing
inefficient
skimming
tanks at the West Side
area and
replacement
with new aerated grit tanks ($130,000,000)
•
Demolition of three existing batteries
of outdated Imhoff tanks
in the
West Side
area and replacement
with two batteries of modern circular primary
settling tanks
($188,000,000)
•
Construction of new circular primary
settling tanks at the
Southwest Area to
replace aging rectangular preliminary settling tanks
($130,000,000)
The total cost of the identified Master Plan projects for the Stickney WRP is
$890,700,000. Several of these projects are under design and will be awarded for construction
starting in 2009.
4
Calumet WRP
Master Plan
The Master Plan for Calumet WRP was completed in 2006. The Master Plan projects for
the Calumet WRP are listed in Attachment 2. Significant projects include:
• New Influent
Pumping Station to replace the existing pumping station
to handle
higher peak flows ($120,890,000)
•
New primary circular
settling tanks replacing
overloaded
aging rectangular tanks,
and grit separation and dewatering facilities replacing undersized grit tanks
($244,600,000)
•
New Aeration Battery D ($100,000,000)
The total
cost
of the identified
Master Plan
projects for the Calumet WRP is
$530,490,000. One of these projects has already been completed (Site Improvements and
Preparation for Construction Traffic), and several other projects are already under construction.
North Side WRP Master Plan
The Master Plan for Calumet WRP was completed in 2007. The Master Plan projects for
the North Side WRP are listed in Attachment 3. Significant projects include:
• A new battery, Battery E
,
comprised of primary settling tanks, aeration tanks, and
final settling tanks
($
315,000,000)
•
New Aeration Battery F ($179,000,000)
•
Demolition of existing undersized final settling tanks and construction of new
larger primary settling tanks for Batteries A, B, and C ($219,000,000)
The total cost of the identified Master Plan projects for the North Side WRP is
$990,480,000. The design of new Battery E is currently underway.
Non-Master Plan Projects
The District's Maintenance and Operations Department and the Engineering Department
meet on an annual basis to discuss capital projects that have been identified by either department
as being necessary for the continued operation of all seven of the water reclamation plants. The
Maintenance and Operations Department justifies and prioritizes the project needs. The
5
Engineering Department organizes the specific requests into projects, creates project numbers for
each project and adds the project to the Engineering Department's project design schedule.
Authority is requested from the Board of Commissioners to add new projects to the Capital
Improvements Program under either the Corporate Fund, Construction Fund, or Capital
Improvements Bond Fund. The projects remain on the design schedule until they are awarded for
construction.
For financial planning purposes, the Engineering Department maintains a 10-year
forecast of capital projects. The 10-year forecast varies throughout the year, as projects are
awarded, new projects are added, and project schedules are adjusted. As of the date of this
testimony, 34 capital improvements projects for the seven water reclamation plants, that are not
considered "Master Plan Projects," have been awarded for construction in 2008 or are scheduled
for award in 2008 or later. These projects are listed in Attachment 4 and total $407,800,000.
Conclusion
The District maintains a Capital Improvements Program to identify, plan for, and allocate
funds for the projects necessary to repair, rehabilitate, replace, and expand the infrastructure of
the water reclamation plants. Project needs are identified through facility planning studies, which
are put into a Master Plan, or on a routine basis by District staff. The total projected estimated
capital cost for the Master Plan projects at the District's three largest plants is $2,411,670,000.
These costs do not include potential project costs for future Master Plan projects at the Egan,
Kirie, and Hanover Park water reclamation plants for which Master Plans as of yet have not been
developed. The total projected estimated capital cost for non-master plan capital projects at all
seven water reclamation plants is $407,800,000. The sum of the above costs is $2,819,470,000.
This represents the baseline financial obligations of the District necessary to keep the water
reclamation plants functioning under the current regulatory framework through the year 2040
6
planning horizon. Costs for infrastructure that would be required to comply with new regulatory
standards would be above and beyond this baseline.
Failure to accomplish these capital improvements projects will jeopardize the District's
water reclamation plants' ability to continue to produce exceptional quality wastewater, will
potentially impede the water reclamation plants' ability to meet the existing NPDES permit
effluent discharge limitations as flows and loads increase, and will allow aging infrastructure to
further degrade to the point that it is beyond reasonable repair or use.
7
Respectfully
submitted,
By:
Thomas E. Kunetz
Testimony Attachments
1.
Master Plan Projects for Stickney Water Reclamation Plant (2008 dollars)
2.
Master Plan Projects for Calumet Water Reclamation Plant (2008 dollars)
3.
Master Plan Projects for North Side Water Reclamation Plant (2008 dollars)
4.
Non-Master Plan Projects for All District Water Reclamation Plants (2008 dollars)
Attachment 1
Master Plan Projects for Stickney Water Reclamation Plant (2008 dollars)
Estimated Construction
Estimated
Proiect
Cost
Contract
Award
Process Air and Central Blower Project
$5,000,000
2006*
New Sludge Thickening Facilities
$173,700,000
2009
Westside Imhoff Battery A and Skimming Tank
Demolition
$30,000,000
2009
Westside Primary Settling Tanks - Battery A
Imhoff Replacement
$150,000,000
2010
Westside Grit Handling Improvements
$130,000,000
2010
Westside Primary Settling Tanks - Battery B
Imhoff Replacement
$108,000,000
2014
Low-pressure Gas Storage for Pressure
Equalization
$10,000,000
2010
Improvements to Gas Transmission Piping, Gas
Conditioning, and Air Intake to Turbine
$4,000,000
2010
Gas Drawoff Modifications & Collection Header
Relief Line
$3,000,000
2014
Southwest Screens Handling Equipment
$5,000,000
2011
Digester Upgrades for Class A Biosolids
$25,000,000
2014
West Side Fine Screen Replacement
$15,000,000
2014
Westside Pump Meter Upgrades
$2,000,000
2014
New Southwest Primary Tanks
$130,000,000
2016
Westside Pump Station Replacement
$100,000,000
2020
Total:
$890,700,000
*Project is under construction
Attachment 2
Master Plan Projects for Calumet Water Reclamation Plant
(
2008 dollars)
Proiect
Estimated
Construction
Cost
Estimated
Contract
Award
Site Improvements and Preparation for
Construction Traffic
$3,000,00
2004*
Central Heating Facility
$23,000,00
2005*
New High Level Influent Pumping Station, and
Low Level Pumping Station Modifications
$120,890,00
2006*
Blowers Nos. 9 & 10 and Air Main Installation
$15,000,00
2009
Sludge Thickening Improvements
$9,000,00
2009
Primary Settling Tanks and Grit Removal
Facilities
$244,600,00
2008
Digester Upgrades for Class A Biosolids
$30,000,000
2014
Selector Zones
$9,000,00
2012
New Aeration Battery D
$76,000,00
2020
Total:
$530,490,00
*Project is under construction or completed
Attachment 3
Master Plan Proiects for North Side Water Reclamation Plant (2008 dollars
Proiect
Estimated Construction
Estimated
Contract
Cost
Award
Master Underground Piping Plan
$980,000
2007*
Sludge Pipeline Condition Assessment
$1,500,000
2008
Aeration Blower Upgrades and Raw Sewage Pump
Upgrades
$42,000,000
2010
Conduit to Battery E and Intermediate Pumping
Station
$64,000,000
2011
Battery E
$318,000,000
2011
Sludge Concentration Tank Improvements
$18,000,000
2012
Grit Dewatering Modification and Sodium
Hypochlorite Feed System Modifications
$5,000,000
2012
New Battery F
$179,000,000
2014
Addition of New South Primary Settling Tanks an
Primary Influent Distribution
$44,000,000
2016
Demolition of Square Primary Settling Tanks;
Addition of New North Primary Settling Tanks;
and Plant Drain Improvements
$30,000,000
2018
Battery C Final Settling Tank Replacement, Air
Distribution and other Improvements
$87,000,000
2019
Battery B Final Settling Tank Replacement, Air
Distribution and other Improvements
$87,000,000
2023
Battery A Final Settling Tank Replacement, Air
Distribution and other Improvements,
$87,000,000
2027
Battery D Air Distribution Improvements
$17,000,000
2028
Coarse Screen Replacement
$8,000,000
2028
Sub-metering and Electrical Needs
$2,000,000
2028
Total:
$990,480,000
*Project is under design
Attachment 4
Non-Master Plan Projects for All District Water Reclamation Plants (2008 dollars)
Estimated
Project
Estimated
Contract
Construction
Cost
Award
Distributed Control System for Solids Processes at
$20,000,000
2008
SWRP
Electrical Distribution Improvements, NSA
$2,550,000
2008*
Aeration Batteries A, B, C, E1, & E2
$13,111,000
2008*
Improvements, CWRP
Diffuser Plate Replacement - Batteries C & D,
$8,000,000
2008
S WRP
R & D Building HVAC Improvements, SWRP
$5,000,000
2008
4160 V Switchgear, Motor Control Centers, Raw
$9,000,000
2008
Sewage Pumps, Motors & Drives Replacement,
EWRP
Drain Valves at Scum Concentration & Post Bldg.
$4,250,000
2008
and Support Structures at Grit Tanks Replacement,
SWRP
E1/W1 Pump Modification at Calumet TARP
$19,000,000
2009
Pump Station, CSA
Electrical Distribution System and Conduit and
$8,750,000
2008
Cable Replacement, SSA
Demolition of Sludge Disposal Building,
$3,946,000
2008
Rehabilitation of Pump & Blower House & Coarse
Screen Building, SWRP
Electrical Distribution System and Conduit and
$2,000,000
2008
Cable Replacement, SSA
HVAC Improvements, SWRP
$5,000,000
2009
Underground Potable and Effluent Water Piping
$1,000,000
2009
Upgrades, NSWRP
C/D Service Tunnel and Connecting Tunnel
$3,500,000
2009
Rehabilitation- Phase 2, SWRP
C/D Service Tunnel Rehabilitation Phase 1, SWRP
$5,200,000
2009
Attachment 4, continued
Proiect
Estimated
Construction
Cost
Estimated
Contract
Award
Aeration Tanks Rehabilitation & Diffuser Plates
Replacement, EWRP, KWRP
$8,000,000
2009
M&O Construction and Police Office
Improvements, CWRP, SWRP
$5,355,000
2009
Office, Shop & Storage Facility Service Tunnel
Rehabilitation and Paving of B&F Streets, SWRP
$5,000,000
2009
Centrifuge Building & Study & Loading System
Upgrades, EWRP
$4,000,000
2009
DCS and Electrical Work HPWRP, KWRP, EWRP
$2,000,000
2009
Electrical Upgrades, CWRP, CSA
$3,500,000
2009
A/B Service Tunnel Rehabilitation - Phase 3,
SWRP
$2,500,000
2010
Pumping Station, LWRP
$81,000,000
2010
Storage Building, NSWRP
$4,210,000
2010
Wet Weather Equalization Pond, EWRP
$20,000,000
2010
Plant Process Computer - D, SWRP
$17,500,000
2010
Final Clarifier Collectors Replacement at Batteries
A, B & C, SWRP
$13,900,000
2010
Digester Facility Improvements, HPWRP
$4,000,000
2010
Lining of Lagoons 3 and 4, CWRP
$10,028,000
2010
A/B & C/D Service Tunnels Rehabilitation - Phase
4, SWRP
$3,500,000
2011
Battery D Air Diffuser System Replacement,
NSWRP
$6,000,000
2011
Proiect
Estimated
Construction
Cost
Estimated
Contract
Award
Retention Pond Deepening Lining Modification,
HPWRP
$19,000,000
2011
R & D Laboratory Facility, SWRP
$80,000,000
2011
Lagoons 14 &15 Lining, CWRP
$10,000,000
2012
Total:
$407,800,000
*Project is under construction
