Transforming Webster’s WPCFto a WRRF

Town Board MeetingThursday, June 24, 2021

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Remember back in January…..

*WRRF – Water Resources Recovery Facility

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Agenda

1. Project Goal Refresher2. Preliminary Engineering Report (PER)/FlexTech Study3. Alternatives by Unit Process4. BioWin Modeling5. Recommendations & ProForma6. Funding & Schedule

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Project Goals

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Project Goals

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To Summarize Your Project Drivers• Outdated & Non-Operable equipmentà Code complianceà

Operator Safety• Regulatory compliance• Increasing tipping fees and imminent landfill closures• Septage & Leachate receiving revenue• Process & Energy optimization• 20-year planning period…..capacity for growth

• NYSEFC/NYSDEC Preliminary Engineering Report (PER)

• NYSERDA FlexTech Study

WPCFàWRRF

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B&L Deliverables

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Alternatives by Unit Process

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WPCF Improvements

Phase ISecondaryClarifiers

WRRFAssetRenewalProject

Phase IEmergencyGenerator

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Headworks Upgrade

1. Upgrade in-kind• Replace Screens in-kind:

• Replace fine screens withnew Duperon ¼” fine screens

• New screen washercompactor and conveyor

• All new gates and valves• Upgrade Grit in-kind:

• Install V-Force baffling systemto optimize the flowconditioning

• Add new grit removal pumpand controls

• Install new classifier

• ~$1.38 M

2. Redundant Grit Vortex• Replace Screens in-kind:

• Replace fine screens withnew Duperon ¼” fine screens

• New screen washercompactor and conveyor

• All new gates and valves• Construct Parallel Grit:

• Existing 10’ diameter vortexto remain

• Construct parallel 10’ dia.vortex with grit pump andclassifier over existing bypasschannel

• ~$1.78 M

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Headworks Upgrade

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Primary Clarifiers

1. Existing Asset Renewal• No Tank Improvements

proposed• Existing primary clarifiers

doing awesome work• Meet TR-16 SOR

• Replace existing chain & flights• Replace primary sludge pumps

with two (2) new 300 gpm, 5HP centrifugal pumps

• Replace valves with three (3)new motorized plug valves

• Replace all plug valves inbasement area

• $~350K

2. Build Additional Clarifier• Construct fourth clarifier• Replace primary sludge pumps

with two (2) new 300 gpm, 5HP centrifugal pumps

• Replace valves with three (3)new motorized plug valves

• Replace all plug valves inbasement area

• $1.0 M

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Primary Clarifier Upgrade

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Aeration Upgrades

1. Activated Sludge• New Fine Bubble Diffusers

• EPDM Diffusers• New PVC grid in tank• New SS air piping

• Automatic DO System• Multiple DO probes at tanks

and control system• Multiple motorized valves

• Three (3) new turbo blowers• Increased capacity and

improved efficiency w/ VFDs• Each at 5,000 SCFM

• ~$1.8 M

2. IFAS• New Course bubble Diffusers

• New diffusers & grid• New air piping• Less efficient air transfer/Higher

DO Required• Reconfigure to Provide Nine(9)

Concrete channels (reduceapproach velocity/headloss)

• IFAS media to promote biofilmgrowth + retention screens

• New Aeration Blowers• Increased capacity due to coarse

bubble• Integrated Control System• Distribution System/Channel• ~$5.0 M

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Aeration System Upgrade

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Thickener Upgrades

1. Retrofit Existing Tanks• Retrofit existing gravity

thickener• Retrofit existing secondary

digester to be gravity thickenertank

• Challenge of pumping to twodifferent elevations

• Construction phasingchallenges utilizing existingtanks

• ~$450K

2. Construct 2 new Tanks• Two new 25’ diameter concrete

gravity thickeners• 12’ side water depth• At grade access from building

side• Tanks provide redundancy and

flexibility• Greater capacity than retrofit• Less impact on current plant

operations during construction• ~$780K

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Thickener Upgrades

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Liquid Receiving

1. No Action• Limited capacity for leachate

and septage receipt• Cannot take outside liquid

sludge/HSOWà LOSS ofrevenue

• High O&M costs• Maintenance Issues

(ineffective for septage)• Very high pump maintenance

cost since existing system notdesigned for septage

• $0 (capital)

2. Receiving Facilities• Leachate Receiving

• Retrofit existing facility (newpumps, valves, piping)

• Efficient Septage Receiving• Receiving Building, 2 ports• Beast screen

• HSOW/Sludge Receiving• Receiving wet well & pump• Retrofit old digester to EQ tank

• New cover & mixing system

• Hauler Billing System• Competitive advantage• ~$1.4 M

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Liquid Receiving

1. No Action• No upgrades• Insufficient existing capacity as

Town flows increase• No ability to accept outside

waste• Inadequate digestion resulting

in unstabilized sludge notmeeting Class B definition

• Future Landfill disposal risk• Safety/Code Issues

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Digester Upgrades

1. No Action• No upgrades• Insufficient existing capacity as

Town flows increase• No ability to accept outside

waste• Inadequate digestion resulting

in unstabilized sludge notmeeting Class B definition

• Future Landfill disposal risk• Safety/Code Issues

• Not an option, facility upgradeessential

2. New Digester + Upgrades• New 500,000 gal Digester

• Precast concrete tank & cover• 50’ diameter

• Mixing System• Retrofit Existing Primary 2

• New mixer & cover• Retrofit Secondary Digester

• New gas holder cover• New mixing system

• Digester Heating System• Gas Safety + Flare• Recuperative Thickening System• ~ $6.0 M

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Digester Upgrades

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Digester Upgrades

1. No Action• No upgrades• Equipment at end of life• Poor dewatering backup in

event of equipmentbreakdown

• Centrifuge Drainage issuescontinue

• Operator safety issues

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Dewatering Upgrades

1. No Action• No upgrades• Equipment at end of life• Poor dewatering backup in

event of equipmentbreakdown

• Centrifuge Drainage issuescontinue

• Operator safety issues

• Not an option, facility upgradeessential

2. New Centrifuge• Retain existing centrifuge as

backup• New Centrifuge (install after

demo of belt press)• Improved Conveyor System• Dewatering building drainage

improvements• Electric Overhead crane• $763,000

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Dewatering Upgrades

• Historical• Preferred Method throughout

2010’s (68% of WWTPs LandfilledBiosolids in 2015)

• Market Driven – Very Low TippingFees

• Current• Odor Issues have resulted in

reduction in biosolids acceptance• Odor Issues @ Landfills – Biosolids

are a significant source• NYSDEC“shift” in position (Climate-

Based Legislation)• Local pressures/Host Community

Acceptance• “Local” Capacity Issues (60 miles)

• High Acres/Mill Seat – FutureAcceptance Unlikely (@ Capacity w/Monroe County)

• Ontario County (current Facility) –2028 Closure

• Seneca Meadows (prior Facility) –Possible 2025 Closure

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Landfill Disposal Trends

Town of Webster Biosolids Disposal

• 2016-2019à $85/ton

• 2019 - 2022à $125/ton*• 47% Increase/3 years

• Post 2022 $ ??????????

*Expires 05/2022

Sludge Dryer Key Project Component

1. Town-Only Sludge 2. Revenue Generating Facility• Cake Receiving Building• Dried Product Carport

• Roll-off box

• Cake dryer• Feed pumping• Odor Control

• Sewer & Gas line relocation• Cake Receiving Bunkers

• Conveyor System

• $6.5 M

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Sludge Drying

• Cake Receiving Building• Dried Product Carport

• Roll-off box

• Cake dryer• Feed pumping• Odor Control

• Sewer & Gas line relocation• ~$6.0 M

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Sludge Drying

• Dried Productà 70-80% Reduction in Weight

• Class A Biosolid Disposal:• Immediate - Reduced Annual tonnage for landfilling• Opportunity - Fertilizer for Town/Community

($0/ton?)

• Extended Runtime = Increased Revenue Opportunity

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Administration Building Needs

Lease - $718/month

Administration Building Expansion & Improvements• Current staffing driving trailer rental• Break/Training Room undersized• Need refined space ADA compliance• Address staff diversity• Office space enhancements• MEP & Architectural updates

Rick’s Office

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Admin Building – Concept Floor Plan

Improvements:- ADA Accessibility- Expanded Breakroom- Expanded Locker- New Office Space- New HVAC System

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BioWin Modeling

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Biowin Modeling

Discharge Parameter Effluent Limitation SPDES LimitModel

PredictedDischarge

Units

BOD5 Monthly Avg. 30 6.0 mg/L

TSS Monthly Avg. 30 18.3 mg/L

NH3 Monthly Avg. 15 4.7 mg/L

TP Monthly Avg. 1.0 0.6 mg/L

pH Range 6 - 9 6.9 mg/L

PHASE 1

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Recommendations & Proforma

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Overall WRRF Site Plan

1. No Action - $$ ???• Plant/Operator safety, reactionary spending, compliance

issues, increasing tipping fees, decreased/unrealizedrevenueà increasing sewer rates, no control over futurerates

2. Webster WRRF Improvements - $31.0 M• Headworks• Aeration Tanks, Blowers & Controls• Digester Complex Upgrades• Dewatering Improvements• Septage/Leachate/HSOW Receipt• Sludge Dryer w/ outside cake receiving• Support System Improvements

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Preliminary Cost Estimate

• Landfill tipping fee savings• Septage revenue• Leachate revenue• HSOW/Outside Sludge revenue• Outside Cake revenue

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ProForma - Revenue Generating Opportunities

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ProForma – Revenue Generating Facility

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ProForma – Revenue Generating Facility

Webster Staff can manipulateProFroma based on changing factors

like tipping fees and utility savings

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Funding & Schedule

• Clean Water State Revolving Fund (CWSRF)• PER Due July 16, 2021• IUP Listingà Subsidized Interest Rate financing

• NYSEFC Water Infrastructure Improvement Act (WIIA)Grant

• 25% Grant, up to $5.0 M• Typically September applicationà “Shovel Ready”• SEQRA + Bond Resolution

• Consolidated Funding Application (CFA) Programs• Due July 30th, 2021

• Appended NYSERDA FlexTech Study• Eligible for NYSERDA Specific Programs (Rotating Timeframe)

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Funding Opportunities

PER Deadlines:• Town Board Workshop – June 24th

• Draft PER to Town – June 30th

• CWSRF Submission Deadline – July 16th

Suggested Next Steps:• Complete SEQR/SERP Coordinated Review• Article 12, Section 202-b Improvement of Facilities• Bond Resolution• Solidify Plan of Finance• Start Project Design – Summer 2021• Design Submission to NYSDEC – Early 2022• Target Bidding – Spring 2022• Construction Start – Summer 2022

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PER Schedule & Next Steps

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