City of Pearland, TX
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Bailey Water Plant Improvements
About. The original Bailey Ground Storage Tank was built in 2004 and was due for rehabilitation. In 2018, the tank overfilled and structurally damaged, putting the tank in decommission. The Ardurra Group completed a structural inspection report and noted that tank repairs would cost approximately $1 million. This is about 65 percent of the cost of constructing a new pre-cast concrete tank. Based on life cycle costs, staff decided to remove and replace the damaged steel tank with a new pre-stressed concrete tank.
Scope. The Bailey water well has elevated levels of manganese and iron that cause taste, odor and appearance issues though the water product itself remains safe for consumption. Phase 1 of this project is the installation of a new 1 MG concrete Ground Storage Tank to replace the welded steel tank. Phase 2 will include: a gravity sanitary sewer line from the Natatorium to the Bailey, a waterline to transport water from the Magnolia Water Plant to the Treatment Plant, and the "green sand" filtration system to treat the manganese and iron issues at the Bailey Plant.
Schedule Info
Base Line | Current | |
Design Start | December 2018 | January 2019 |
Bid Start | April 2021 | November 2021 |
Construction Start | January 2022 | May 2022 |
Proposed Construction Completion | October 2023 | October 2023 |
Below is information pertaining to the Budget and Funding of the project. Last updated June 2023.
Bailey Water Plant
Funding Sources | |
General Revenue - Cash | - |
Certificates of Obligation | - |
Water/Sewer Revenue Bonds | $14,440,000 |
Impact Fee -Debt | - |
Other Funding Sources | - |
Total Funding Sources | $14,440,000 |
Expenditures | |
PER | - |
Land | $3,545 |
Design | $742,031 |
Construction (Tank) | $1,596,570 |
Construction (Pre-treatment) | $11,803,491 |
Construction Materials Testing | $180,723 |
FF&E | - |
Total Estimated Expenditures | $14,326,360 |
Project Contingency | $113,641 |
Staff will be requesting additional funds during the mid-year adjustments
Bailey Sewer Line
Funding Sources | |
General Revenue - Cash | - |
Certificates of Obligation | - |
System Revenue - Cash | $30,000 |
W/S Revenue Bonds | $1,512,000 |
Impact Fee - Debt | - |
Other Funding Sources | - |
Total Funding Sources | $1,542,000 |
Expenditures | |
PER | - |
Land | $3,500 |
Design | $50,438 |
Construction | $1,401,112 |
Construction Management/Inspection | - |
Construction Materials Testing | $48,505 |
FF&E | - |
Total Expenditures | $1,503,555 |
Project Contingency | $38,445 |
March
Highlights:
- The construction is 83% complete in 72% of the contract time.
- The 5 aeralator structures are all erected, welded, and tested, and the interior painting has been completed.
- The pumps and piping from the aeralators to the backwash pond are installed and tested.
- The wastewater piping from the building to manhole and from the manhole to the new lift station has been installed and tested.
- The Motor Control Center (MCC) building is erected, including the metal roof, drywall framing, and exterior brick work.
- Overhead door is installed, and interior doors are delivered for installation at MCC.
- The underground utilities, to include electrical duct banks, are complete at Bailey WTP and site paving is to begin.
- Site drainage is complete. A section of sidewalk that surrounds the Bailey WTP site is to be replaced via a change order to address a low spot that is causing ponding & will connect to the site drainage.
- Generators are installed and plumbed at both the Bailey and lift station sites. Gas meters are ordered and pending installation by CenterPoint Energy.
Upcoming Work Items:
- Complete exterior painting of aeralators, pumps, and discharge piping.
- Excavation of backwash pond. Once dug, the gravity line from the backwash pond to a new manhole within Bailey WTP will be installed and tested.
- Continue installation of vaults and inlets within the Bailey site
- Complete paving and flex base road installation at the lift station.
- Installation of PVC chemical lines.
- Complete the exterior and interior architectural finishes for the MCC building.
November
Highlights:
- The transmission line from the Magnolia Water Plant to the Bailey Water Plant has been completed.
- The sanitary sewer line from the Natatorium to the Bailey Water Plant is complete.
- The pad for the control building has been formed and all underground Mechanical/Electrical/Plumbing (MEP) work has been completed and passed inspection.
- The foundation for the five aeralater treatment units have been poured, along with the equipment riser pads.
- The seal slab for the lift station has been completed and the station walls have been poured, cured, and sunk below grade.
- The lift station deck has been poured.
Upcoming Work Items:
- The control building slab will be formed and poured.
- The CMU block installation on the control building will begin.
- The formwork and rebar for the structure of the chemical containment storage area will be completed, and the concrete will be poured.
- Housekeeping pads will be poured around aeralater foundation.
- The 17’ aeralaters are scheduled to be delivered late-November 2022.
- The work will begin on the elevated deck for the lift station.
February
Highlights:
The 2.8 million gallon per day (MGD) water well at the Bailey water plant and the 1.4 MGD water well at the Magnolia plant are vital contributors to the City’s distribution system capacity for drought contingency and to meet peak day demands. Both water wells are necessary per our City Water Model to meet regulatory capacities as the City builds-out. Staff has maintained a log of numerous customer comments and complaints regarding brown/rusty colored water within the areas served by these wells. These complaints, and subsequent testing, indicate elevated levels of iron and manganese in the groundwater. While these minerals are secondary constituents and do not affect the safety of the water, manganese and iron are considered nuisance constituents due to the color and taste they can impart. Due to the complaints and the ability to provide water from other sources in the City, the wells were taken off-line until a treatment system could be installed to remove these minerals.
Phase 1 of this project was the design and installation of a new 1 MG pre-stressed concrete Ground Storage Tank to replace the existing welded steel tank at the Bailey WTP. Construction was completed in June 2020.
Phase 2 includes: construction of a water transmission line to transport water from the Magnolia Water Plant to the Bailey for treatment, a treatment system (Aerelater) to remove the iron and manganese from the groundwater produced by both Bailey and Magnolia wells, construction of a new Lift Station and Force Main to discharge backwash from the treatment system to the sanitary sewer at Veterans , SCADA integration, and removal of the damaged steel Ground Storage Tank. The Aerelater treatment system utilizes a filtration reactive media of potassium permanganate, otherwise known as “green sand”, to remove these constituents from the water. Once completed, this project will allow these wells to return to service.
Upcoming Work Items:
Three items will be recommended at the February 28th City Council meeting:
1. Staff will recommend award the construction contract to LEM Construction Co, Inc. in the amount of $12,593,561.91.
2. Staff will recommend the award of Construction Materials Testing contract to Terracon Consultation, inc. in the amount of $212,735.00.
3. Staff will recommend approve an additional appropriation of $912,000 from Fund 539 Revenue Bond 2022 Fund to the Bailey Sewer Line (WW2007) project and $1,600,000 from Fund 539 Revenue Bond 2022 Fund to the Bailey Water Plant Improvements (WA1901) project.
2021
September
Hightlights:
Council awarded a design contract to eHT in January 2019. Phase 1 of this project installed a new 1 MG prestressed concrete Ground Storage Tank (GST) to replace the existing welded steel tank. Construction of Phase 1 was awarded to DN Tanks in July 2019, and the Phase 1 was completed in June 2020.
Phase 2 now includes: A treatment system (Aerelater) to remove the iron and manganese, installation of a waterline to transport water from the Magnolia Water Plant to the Bailey Treatment Plant, installation of a new local Lift Station and Force Main to discharge backwash from the treatment system to the gravity sanitary sewer line at Veterans and Bailey, SCADA integration, and removal of the existing steel GST.
Next Steps:
There is approximately one month remaining to finalizing the design for review by the Technical Review Committee (TRC) prior to issuing a bid-level plan set with the bid advertisement. Upon approval of the amendment, eHT will implement these final details and submit the 100% plans, specifications, and construction estimate. Advertisement for proposals is scheduled for November, with a mandatory pre-bid conference and site visit following. The project will utilize the Competitive Sealed Proposal (Local Gov’t Code Chapter 2269), subchapter (B) procurement process.
Once the project has been bid and awarded the construction is expected to begin in January 2022. The construction phase is anticipated at 18 (eighteen) months to substantial completion.
January
Phase 2 Highlights:
- Staff received 60% drawings 11/12/20 and a review meeting will be held with City Engineering Staff, Consultant, and user groups on 12/15/20 to discuss and review comments.
- Staff provided Consultant with current TCEQ Corrosion Control Study for review to ensure proposed treatment system meets reported methods and measurements City-wide. Existing site chemical tanks for corrosion inhibitor will be retained and remain in operation.
- The Magnolia well water contains similar levels of iron and manganese and any effort to address water quality issues for the greater area must include water from both wells. For that reason Magnolia well was included in the project and will be piped to the Bailey Treatment Plant for treatment of the water and then the water can be utilized in the system.
- Design of water transmission line from Magnolia well site to Bailey Treatment Plant has been completed. Design of waste water sewer line to the collection system is complete.
- Project scope includes this additional piping, valving and operational modifications at Magnolia well site and the transmission line to transfer ground water from Magnolia to the Bailey treatment facility to address water quality issues from the Magnolia well at the one location. Treatment capacity at the Bailey Plant has been increased to handle this additional flow from Magnolia (approx. 1.4mgd) for a total of approximately 4.3MGD of treatment capacity.
- Per the recently completed water model, along with projections of population, the City will need to have wells, along with the supplies from the Surface Water Plant and the Alice plant in working operation to provide drinking water to meet the peak demands for the forecasted year of 2030.
- Due to market fluctuations on equipment and materials and moving the design from 60 towards 90% has provided the project with the most current engineering costs estimates. The current estimate exceeds the existing budget.
- Based on the additional cost, an analysis was done to see if this is the most cost-effective way to deliver the required peak demands in the future. Staff look at the potential for new wells or other water sources. However, with the quality needed and the existing information on the quality of water, from the existing two wells, it is highly likely that any new wells in the area will yield the same need for water treatment. Additionally, other sources would require investment in all new infrastructure. With the existing infrastructure in place (wells, pumps, piping and tanks), the addition of the treatment facility to the Bailey water plant is the most cost-effective methodology to treat water and meet the water demands now and for the future.
Upcoming Work Items:
- Approval from BNSF for water transmission line crossing below the Railroad at Magnolia pump station.
- Design consultant will be completing 90% drawings to be submitted for Staff review in January using comments from 60% review meeting. Consultant will provide project manual and technical specifications with 90% submission.
- Details for the Motor Control Center (MCC) and Laboratory Building are being finalized and will be submitted by the consultant for permit approval.
- Water line easement approval from the (2) remaining landowners for the Magnolia transmission line is being finalized. The City currently holds an agreement for these locations from a previous project (Canterbury Water Line).
August
Phase 1 Highlights:
Since the last project update the contractor, DN Tanks, has completed the following construction tasks:
- Substantial completion walk-thru was conducted on May 15, 2020 and attended by City of Pearland Water Department, Engineering and Capital Projects, engineer of record, and contractor.
- A punch list of items that needed additional attention was created and communicated to the contractor for completion prior to the City’s final acceptance.
- A final inspection was conducted June 15, 2020 to conclude all punch items completed . All pending items were complete and required closeout documents submitted. The project is currently awaiting 95% germination of hydroseed to release retainage and close the project.
- Construction phase 1 was completed on time and within City’s planned budget.
Phase 2 Design Update:
- Enprotec/Hibbs & Todd (eHT), the consulting engineer, has begun the BNSF railroad permit application to be submitted with final plans. The permit is required for the line from the Magnolia plant to cross under the railroad’s right-of-way and tracks.
- Staff is working on easement acquisition needs based on proposed location and alignment of the wastewater line along Bailey Rd. from the Natatorium to the Bailey Plant, and water transmission line from the Magnolia well to the Bailey plant. The wastewater line will be sized to serve future Fire Station 7 and potential future development.
- Staff reviewed the 30% plans and have sent them back to eHT to review and incorporate into the next submittal.
- Staff pursued proposals from demolition contractors to remove the existing steel 1.0 MG GST. Offsetting the cost to demo with an incentive of valuable scrap materials did not decrease the proposal to budgeted amount. It was concluded that including the demo scope in the Phase 2 project bid documents would provide the City with the best value.
Phase 2 Upcoming Work Items:
- Evaluation of cost and maintenance needs for epoxy-coated carbon steel compared to stainless steel in order to determine appropriate material for AERALATOR treatment process unit.
- Design of proposed structure that will protect the liquid bleach bulk storage tanks from damaging UV rays and excessive heat from the sun. The cover will be a simple design over the tanks, which will also be double wall and insolated to reduce degradation of tanks from the gaseous chemicals.
- Updated draft Basis of Design Report (BODR) incorporating the sanitary sewer line and addressing comments discussed at last team meeting. BODR will include a revised Opinion of Probable Construction Costs (OPCC) which will detail this scope as a separate item.
- Design consultant to submit 60% construction documents for Staff review in mid-August. Once reviewed and all comments have been addressed, consultant will submit for TCEQ review and approval.
April
Phase 1 Highlights:
Since the last project update the contractor, DN Tanks, has completed the following construction tasks:
- Casting of tank wall panels were completed and met structural specification.
- 365-ton crane was delivered to the ite and staged for wall panel installation
- On January 29, 2020, the contractor-initiated perimeter wall-panel erection activities and dome panel installation.
- Ground storage tank (GST) erection was completed on February 1, 2020, crane demobilized from job site.
- Completed dome slots that interconnect with each dome panel.
- completed pouring all panel wall slot-concrete which provides a monolithic seal from panel to panel.
- Completed the wire cover (Prestressing) and shotcrete application over the exterior surface of the GST.
- As of March 16, 2020, the GST erecting is complete.
Phase 2 Design Update:
- Draft Basis of Design Report, which is required by TCEQ, was submitted for review in early February.
A review meeting was held on February 19th to discuss the report. Outcomes are listed below. - The bleach storage tank will be located outdoors instead of inside climate control. eHT
recommended insulating the tank to help resist degradation of the tank contents. - The WesTech AERALATOR treatment plant will be located outdoors as well. This option was
preferred for accessibility for O&M related items and constructability purposes. - Additional admin space will not be included at the Bailey site as part of the improvements project.
Tentatively, the climate-controlled building will only consist of a small control room, lab, and uni-sex
restroom. - The project will include the installation of a gravity sewer system from the collection line at Veteran’s
and Bailey. The gravity line will extend to the water plant to remove the need for a lift station to
dispose if the backwash water. The gravity sewer line will also be able to provide sewer service
for the future Fire Station #7. - The report discusses draining the backwash system to a Lift Station located on-site and then
pumping it to a detention pond. The ability to bring a gravity sewer line to the site, will remove the
need for a lift station. Due to the volume and high flow for the backwash cycle, eHT and the City
discussed gravity flowing from the AERALATOR process units into a backwash pond that will be
deep enough to have the capacity to handle the backwash cycle of the units. The perimeter of the
pond will be built up slightly above natural grade (i.e. a perimeter berm) to minimize water intrusion
during storm events, and the backwash discharge will be controlled in a manner to lengthen out the
time of discharge to the gravity sewer system thus reducing surges at the receiving WWTP and
associated stations. There is ample land available at the current site to implement this design option
and reduces cost impacts to the project by eliminating the lift station and force main. This also
removes future O&M costs for another LS.
January
Phase 1 Highlights:
The Notice to Proceed (NTP) for the new ground storage tank (GST) and on-site piping construction project was issued for November 4, 2019. Since the NTP, the contractor has completed the following:
- Contractor mobilized on site.
- Submitted all submittals associated with the project for Engineer review/approval.
- Contractor's excavation crew cut out the proposed GST's 89-foot diameter layout and excavated down 7 feet from natural ground.
- Imported and compacted structural fill (TXDOT-Flex base) as specified in the project's geo-tech report.
- Formwork for foundation slab and perimeter footing was completed and concrete was placed on January 7, 2020.
- Tank crew began to build wall "casting beds" out of lumber. After which, the proposed GST walls were formed and casted with concrete from within the casting bed.
- Tank crew also formed and poured the dome panel segments subsequent to the wall panels.
- Installed the proposed 18" ductile iron inlet yard piping and prepped-formwork for concrete encasement.
Phase 2 Design Update:
- The pilot testing for the green sand filter was completed in July 2019. the resulting recommendation was to install a "green sand" filtration system at the Bailey Plant to remove the iron and manganese from the ground water.
- EHT is currently working on the full-scale treatment plant design which includes: the construction of a Water Treatment Plant (WTP) and the installation of a waterline to transport water from the Magnolia Water Plant to the Treatment Plant. The treatment Plant building will include a lab and office space.
- This project also consists of the design and installation of a gravity sanitary sewer line which will carry the backwash discharge from the Bailey WTP site to an existing sanitary sewer line at the intersection of Bailey Road and Veterans Drive. The line will also provide service to he future Fire Station 7 site.
- EHT completed survey for the Bailey Water Plant Site at the beginning of the month.
November
Phase 1
- The plans for the new GST were bid out in June 2019 and the construction was awarded to DN Tanks on August 26, 2019. Construction will began on that project in November 2019.
Phase 2
- The pilot testing for the green sand filter was completed in July 2019. The resulting recommendation was to install a "green sand" filtration system at the Bailey Plant to remove the iron and manganese from the ground water. Once the treatment process was selected, EHT began working on the full-scale design.
August
- Bid and Award
- Advertising for the project commenced on June 19, 2019
- Two contractors submitted bids
- $1,581,785.00
- Submitted by DN Tanks, Inc.
- Bid within the 11 percent of engineer's construction estimate of $1,427,000.00
- $1,773,400.00
- $1,581,785.00
- DN Tanks, Inc.
- Currently working with the City on FM 521 Grand Storage Tank
- Work is proceeding well; reference checks and reviews of qualifications yielded favorable results
- Engineer provided a Recommendation of Award to DN Tanks.
- Award
- Staff will recommend the Council award the contract to DN Tanks, Inc. in the amount of $1,581,785.00
- Contract
- includes 180 calendar days for substantial completion with an additional 30 days to achieve final completion
- Staff will hold pre-construction conference in September and issue the Notice to Proceed.
- Expected completion date March 2020.
November
- Project Background
- Bailey Road Water Plant
- well and side have a history of high iron and mangese lvel
- long-running complaints have emphasis in the winter when water usage decreases
- iron and manganese not dangerous to the public, but can cause aesthetic complaints related to taste, odor, and appearance
- Water Production Staff have historically used polyphosphates and zinc orthophosphates to keep
the iron and manganese in solution, referred to as “sequestering”- has a limited effective life of 48 to 72 hours and during low use periods, typically in the winter months, these materials drop out of solution and show up as “dirty water” “brown water’ and “rusty water” complaints.
- Flushing the distribution system is a temporary solution and leads to low water pressure in distribution area; flushing also results in wasting of already treated water
- well and side have a history of high iron and mangese lvel
- Magnolia Road Well
- recent history of containined dissolved hydrogen sulfide gas
- produces a mild rotten egg smell and can contribute to taste and odor issues
- recent history of containined dissolved hydrogen sulfide gas
- Both scenarios with Bailey and Magnolia highlight the need to provide additional treatment technology at the sitres to remove offending constituents prior to the introduction of this water to the distribution system
- Bailey Road Water Plant
- Project Planning
- Two phases
- 1. Engineer performs one week pilot test
- Testing of three potential technologies to determine the best methodology for removing iron, manganese, and hydrogen sulfide gases
- 2. Design of the selected treatment method along with other components associated with treatment solution, such as site piping modifications and design of a new concrete ground storage tank and accompnying components.
- 1. Engineer performs one week pilot test
- Two phases
- Budget
- Total contract value to encompass the work for design is $372,460.00
- Basic services: $335,200.00
- Additional services: $37.260.00
- Total contract value to encompass the work for design is $372,460.00