kwa - preliminary engineering report - sept 2009 - appendix 6

8/7/2019 KWA - Preliminary Engineering Report - Sept 2009 - Appendix 6

1/13

Jones&HenryEngineers,Ltd.2000WestCentralAvenueToledo,Ohio43606

419.473.9611www.jheng.com

Lake Huron Water Supply Study

Appendix 6

Technical Memorandum

Transmission Lines

Karegnondi Water Authority

o City of Flinto Genesee Countyo Lapeer Countyo Sanilac County

February 16, 2009


2/13

Jones & Henry Engineers, Ltd.

Lake Huron Water Supply Study758-6259.001 1 Appendix 6

6.1 TRANSMISSION LINES

6.1.1 General

This technical memorandum describes the general design criteria for raw water transmission lines as

components of the Lake Huron Water Supply Study.

6.1.2

1.

Transmission Lines

The Project has five major transmission pipe lines. Four are raw water lines and one dual line is finishedwater.

The waterlines are sized to maintain a velocity of 5 feet per second or less under all operating conditionsand have operating pressures less than 200 psi.

A detailed hydraulic analysis has not been performed as part of the planning study but it will be requiredas part of the detailed design of the system.

203,280 feet of 72-inch diameter steel pipe (cement mortar-lined) or pressure concrete cylinderpipe (PCCP). Both pipe materials have similar installed costs. The actual material should beselected based on costs and conditions at the time of construction. The breakdown of costs forPCCP will be used for the remainder of this technical memorandum.

The Lake Huron Transmission pipeline conveys raw water from the Lake Huron Pump Station tothe Raw Water Reservoir, approximately 38.5 miles west of the pump station.

Lake Huron Transmission

2.77,760 feet of 54-inch diameter ductile iron pipe (DIP). Costs are based on DIP Class 200 in thistechnical memorandum. The actual class of pipe must be determined during the design phase.

The North Transmission pipeline is one of two lines to convey raw water from the Reservoir tothe Genesee County WTP or serve as the first leg of the raw water supply to the Flint WTP. Therewill be valves near the Genesee WTP to allow either alternate to be implemented.

North Transmission

3.44,265 feet of 60-inch DIP, and 29,186 feet of 54-inch diameter DIP. Costs are based on DIPClass 200 in this technical memorandum. The actual class must be determined during the designphase.

The South Transmission pipeline is the other line that will convey raw water from the Reservoirto the Lapeer and Genesee County WTPs or serve as the first leg of the raw water supply to theFlint WTP with the north transmission serving as a backup. There will be valves near the GeneseeWTP to allow either alternate to be implemented.

South Transmission

4.74,560 feet of 48-inch diameter DIP. Costs are based on DIP Class 200 in this technicalmemorandum. Pipe class(es) need to be determined during the design phase.

Flint Transmission


3/13



The Flint Transmission pipeline conveys raw water from the North Transmission pipeline to theFlint WTP. The Flint Transmission pipeline can also be fed by the South Transmission pipelinepassing through the Genesee WTP site as a backup to the North Transmission pipeline.

5.28,420 feet of 42-inch DIP. Costs are based on DIP Class 200 in this technical memorandum.Pipe class(es) need to be determined during the design phase.

Finished water from the Genesee County Water Treatment plant will be conveyed to the existingHenderson Road Pump Station by two parallel 42-inch pipelines. The pipelines will beconstructed in separate parallel trenches. The pipe length reflects total pipe length of the twopipelines.

See Appendix 5 for additional detail of routing, alignments, and surface conditions for each of thefive Transmission Pipelines.

6.1.3

Genesee County Finished Water Transmission

1.

Pipe Installation

The following is a discussion of components that are included in transmission pipeline and used todevelop the estimate of costs. They are presented in the order shown on the estimate forms. The estimateforms follow this discussion.

The 72-inch pipe will be either cement mortar lined steel or pressure concrete cylinder pipe ratedfor 200 psi pressure. All other pipe for the project is DIP, with push-on joints with integral jointrestraint as needed. Pressure Class 200 has been assumed here, but the actual class proposedneeds to be determined during design.

Material prices for pipe are based on manufacturers pricing December 2008.

The installation rates for the pipelines are based on production rates for similar pipe sizes and soiland site conditions. Information obtained through conversation with contractors.

72-inch pipe installed at a typical rate of 300 ft/day60-inch pipe installed at a typical rate of 250 ft/day48 and 54-inch pipe installed at a typical rate of 300 ft/day48-inch pipe installed in developed areas (in Flint vicinity) at a rate of 200 ft/day.42-inch pipe installed at a typical rate of 300 ft/day

DIP Pipe Encasement Polyethylene Wrap Polywrap 4 mil HDT

Pipe

2.A standard pipeline crew for installation of the transmission pipelines consists of seven-mancrew.

Assume $550/day/ manLabor cost = $3,850/day

Labor


4/13



3.Typical equipment for the transmission line installation:

375 Cat Excavator

950 Cat LoaderD-8 Dozer(trucks included in hauled materials prices)

Equipment

4.Fuel cost for the listed equipment is $973 per day.This is based on 350 gallons per day consumption and diesel at $2.78 per gallon (December2008).

Fuel Costs

5.The pipe installation will use a Type 4 trench.

The bedding with this installation will be sand or gravel from 6 to 8-inches below bottom of thepipe to one foot above the top of pipe. Width of pipe trench at the bottom will be pipe diameterplus 12-inches either side.

Sand will be Class 2 at $5.50 per tonStone will be 6A at $18.00 per ton

Costs have been included to haul bedding materials to the site and haul out spoil materialsassociated with the bedding material displacement.

Typical cost for hauling materials to and from the job, including labor and equipment, is $5.00per cubic yard.

The pipeline construction in the project area is likely to encounter wet conditions in somesections which will require dewatering. For the project estimates, 20 percent of the trench lengthis assumed to require dewatering (See Item 6 below). The trenches in dewatered areas will have6A stone used for bedding from the trench bottom to the spring-line of the pipe instead of sand.The remainder of backfill around the pipe will be sand.

The two types of pipe bedding for the project are noted as wet-construction and dry-construction.

Pipe Bedding

6.The pipe installation will require dewatering due to the location of the project and the nativeconditions. As noted, it is assumed that 20 percent of the pipe installation will require dewatering.

Typical cost for dewatering is $40 per foot.

Note: Additional support for the installed pipe due to poor soils such as peat or marl needs to beevaluated after detailed soils investigations are completed.

Dewatering

7. Specials & Appurtenances


5/13



The routes of the various pipe line and the installation location in-paved roads or gravel roads,adjacent to roads in easements, or cross-country in-easement are presented in Appendix 5. Therouting and shifting alignments will require pipe fittings in most cases to achieve the deflections.For the transmission pipeline estimates, pipeline offsets are done using two 45-degree bends.

Right-angle bends are also done using two 45-degree bends.

The costs represent material cost only. The installation cost is included in the pipe constructioncost.

8.Air release valves will be installed along the pipe line as needed for proper operation. Previousinitial designs for the Lake Huron transmission main were used to develop preliminary quantities.The air release valves will be installed in concrete chambers, 9 feet by 9 feet with adequate heightfor the air release valve.

Air Release Valves

9.Valves will be installed in the transmission main at approximately six (6) mile intervals to isolatethe line for emergencies and routine inspections. The valves will be knife gate valves with electricactuators. The valves will be pressure rated for 200 psi where necessary.

The actuators will be either 480V 3-phase, or 240 V single-phase. The single phase power willallow power to be more readily supplied to the remote sites along the transmission lines.

The valve assemblies will be installed in reinforced concrete vaults with manhole access. The topslab of the vault will be removable.

The cost represents the complete installation including the valve, actuator, and concrete chamber.

Isolation Valves

10.Blow-off valves will be installed on the transmission line for flushing sections of lines. They willprovide a flow adequate to suspend and transport sediment as needed.

The blow-off valve assembly will consist of a tee fitting with 18-inch side outlet on thetransmission line with an 18-inch gate valve in a separate valve chamber and approximately 100feet of 18-inch DIP to transport the blow-off flow to a discharge point.

The cost represents the complete installation including the fitting, valve, piping and chamber.

Blow-Off Valves

11.Flushing hydrants will be installed along the route for construction needs and routine access forthe operation and maintenance of the transmission lines. These will be typical hydrant assembliesconnected to the transmission line installed at 18,000 to 20,000 feet intervals.

Flushing Hydrants

12. Pipe in Tunnel


6/13



It will be necessary to install the pipe in tunnels at several locations. The tunnel construction isbased on a steel liner plate tunnel approximately 12-inches larger than the outside diameter of thepipe bells. The transmission line will be installed after the tunnel is complete. Tunnel constructionwill be used to cross State Highways, active Railroads, and streams and rivers. The location of thepipe in tunnel installation is addressed in Technical Memorandum 5.

The price to construct the primary tunnel, without pipe costs, for the 48-inch through 72-inch pipeis $2,135 per foot.

6.1.4 Construction Schedule

The construction schedule for the transmission lines is based on several factors. The key factor is the dailyproduction rate of pipe installation, estimated to be between 200 to 300-feet per day. Other factors arelead time to begin getting piping and equipment delivered to the site, time needed to construct the variouschambers for the valves and other appurtenances, and the time to complete surface restorations which willbe on-going throughout the project. Seasonal limitations must also be taken into account.

The transmission lines construction schedule is impacted by the number of construction contracts to beused for each of the five transmission line projects.

6.2 ANNUAL OPERATIONS AND MAINTENANCE COSTS

6.2.1 Annual Operating Costs

The following assumptions were made for operating costs:

1. Power cost based on $100 per month per valve for electrically-operated knife gate valves.

2. Direct Labor Cost of $25 per hour with a fringe benefit rate of 1.62.

This estimate assumes a two-man crew will inspect and exercise the valves and chambers along all routessix times per year at 30 hours per inspection.

6.2.2 Annual Maintenance Costs

Maintenance costs were assumed as follows:

1. Valves and Hydrants 2-1/2 percent of original costs (40 years)

2. Pipelines 1-1/3 percent of original cost (75 years)


7/13



Table 6-1Annual Operations and Maintenance Costs

Operating CostsLabor $14,580

Power $22,800Subtotal $37,380

Maintenance CostsValves & Hydrants 2-1/2% $197,490

Piping 1-1/3% $1,904,045

Subtotal $2,101,535

Total O&M Costs $2,138,915

6.3 COSTS ESTIMATES

6.3.1 Cost Estimates

Cost estimates for the five transmission lines are on the following pages.


8/13

Pipe Size 72 inches

Total Length 203,280 feet 38.5 miles

Open Cut Length 202,640 feet

Tunnel-Installed 640 feet

MATERIAL (Open Cut) Length (ft) $ / LF TOTAL

Cost of Pipe 202,640 380.00$ 77,003,200$

LABOR Days (Cost/Day) TOTAL

Labor 676 3,850.00$ 2,602,600$

EQUIPMENT Days (Cost / day) TOTAL

Equipment 676 1,522.00$ 1,028,872$

FUEL Days Daily Usage (gl) Cost (gl) TOTAL

Fuel 676 350 2.78$ 657,748$

PIPE BEDDING Length (ft) Volume (cy) Unit Cost TOTAL

Wet Construction

Stone 6A 40,528 18,537 18.00$ 333,659$Sand Class 2 40,528 22,039 5.50$ 121,215$

Hauling (Bedding Material) 40,576 5.00$ 202,878$

Haul Away Spoils 70,048 5.00$ 350,242$

Dry Construction

Sand Class 2 162,112 162,302 5.50$ 892,663$


Haul Away Spoils 280,194 5.00$ 1,400,968$

SUB TOTAL 4,113,136$

DEWATERING Length (ft) $ / LF TOTAL

Dewatering 40,528 40.00$ 1,621,120$

P I P E S U B T O T A L 87,026,676$

COST OF PIPE /ft 428.11$

SPECIALS Unit Cost TOTAL

Air Release Valve Units 46 units 29,000$ 1,334,000$

Isolation Valve Units 7 units 231,000$ 1,617,000$

Blow-off Valve Unit 11 units 76,500$ 841,500$

Flushing / Hydrant 11 units 2,000$ 22,000$


Tunnel Installed Sections

Black River 300 ft 2,515$ 754,500$

Hyway M-19 120 ft 2,515$ 301,800$

Railroad Crossing 100 ft 2,515$ 251,500$

Van Dyke Rd. 120 ft 2,515$ 301,800$

SUB TOTAL 640 ft 1,609,600$

SUB TOTAL 92,450,776$

OVERHEAD & PROFIT 15% 13,867,616$

G R A N D - T O T A L 106,318,393$

LAKE HURON TRANSMISSION

Jones Henry Engineers, Ltd. 1/20/2009


9/13

Pipe Size 54 inchesTotal Length 77,760 feet 14.73 milesOpen Cut Length 77,390 feetTunnel-Installed 370 feet


Cost of Pipe 77,390 285.00$ 22,056,150$


Labor 258 3,850.00$ 993,300$


Equipment 258 1,522.00$ 392,676$


Fuel 258 350 2.78$ 251,034$

PIPE BEDDING Length (ft) Volume (cy) Unit Cost TOTALWet Construction

Stone 6A 15,478 5,570 18.00$ 100,265$

Sand Class 2 15,478 6,717 5.50$ 36,942$


Haul Away Spoils 19,491 5.00$ 97,454$

Dry Construction

Sand Class 2 61,912 49,148 5.50$ 270,315$


Haul Away Spoils 77,963 5.00$ 389,816$


DEWATERING Length (ft) $ / LF TOTAL

Dewatering 15,478 40.00$ 619,120$

P I P E S U B T O T A L 25,514,247$


SPECIALS Unit Cost TOTALBends 40 units 11,014$ 440,561$Air Release Valve Units 17 units 25,000$ 425,000$

Isolation Valve Units 4 units 153,000$ 612,000$





Lapeer Road 120 ft 2,420$ 290,400$

Flint River 250 ft 2,420$ 605,000$

SUB TOTAL 370 ft 895,400$

SUB TOTAL 28,171,309$


G R A N D - T O T A L 32,397,005$

NORTH TRANSMISSION



10/13

Pipe Size 60 inches




Pipe Size 54 inches

Total Length 29,186 feet 5.53 milesOpen Cut Length 29,186 feet

Tunnel-Installed - feet


Cost of Pipe 60 inches 43,995 328.00$ 14,430,262$

Cost of Pipe 54 inches 29,186 285.00$ 8,317,872$


Labor 244 3,850.00$ 939,400$


Equipment 244 1,522.00$ 371,368$


Fuel 244 350 2.78$ 237,412$


Wet Construction

Stone 6A 14,636 5,267 18.00$ 94,810$

Sand Class 2 14,636 6,351 5.50$ 34,933$


Haul Away Spoils 18,431 5.00$ 92,153$

Dry Construction

Sand Class 2 58,544 46,475 5.50$ 255,610$


Haul Away Spoils 73,722 5.00$ 368,611$


DEWATERING Length (ft) $ / LF TOTALDewatering 14,636 40.00$ 585,442$

P I P E S U B T O T A L 26,018,340$



Bends 24 units 11,014$ 264,337$

Air Release Valve Units 17 units 25,000$ 425,000$

Isolation Valve Units (60") 2 units 184,000$ 368,000$

Isolation Valve Units (54") 2 units 153,000$ 306,000$





Lapeer Road 120 ft 2,463$ 295,560$

Flint River 150 ft 2,420$ 363,000$


SUB TOTAL 28,186,287$


G R A N D - T O T A L 32,414,230$

SOUTH TRANSMISSION



11/13

Pipe Size 48 inches



Special Installation Sewer Area 26,400 feet 5.00 miles



Cost of Pipe 74,140 222.00$ 16,459,080$


Labor (Normal Installation) 160 3,850.00$ 616,000$

Labor (Sewer Area) 132 3,850.00$ 508,200$



Equipment 292 1,522.00$ 444,424$

FUEL Days Daily Usage (gl) Cost / gl TOTAL

Fuel 292 350 2.78$ 284,116$


Wet Construction

Stone 6A 14,828 5,336 18.00$ 96,054$

Sand Class 2 14,828 6,435 5.50$ 35,391$


Haul Away Spoils 18,672 5.00$ 93,361$

Dry Construction

Sand Class 2 59,312 47,084 5.50$ 258,963$


Haul Away Spoils 74,689 5.00$ 373,446$



P I P E S U B T O T A L 20,056,431$



Bends 50 units 19,793$ 989,672$

Air Release Valve Units 17 units 29,000$ 493,000$

Isolation Valve Units 3 units 84,000$ 252,000$





State Road 120 ft 2,357$ 282,840$

Flint River 300 ft 2,357$ 707,100$


SUB TOTAL 23,095,042$


G R A N D - T O T A L 26,559,299$

FLINT TRANSMISSION



12/13

Pipe Size 42 inchesTotal Length 28,420 feet 5.38 milesOpen Cut Length 28,420 feet


MATERIAL Length (ft) $ / LF TOTALCost of Pipe 28,420 171.00$ 4,859,820$

LABOR Days (Cost/Day) TOTALLabor 95 3,850.00$ 365,750$

EQUIPMENT Days (Cost / day) TOTALEquipment 95 1,522.00$ 144,590$

FUEL Days Daily Usage (gl) Cost / gl TOTALFuel 95 350 2.78$ 92,435$

PIPE BEDDING Length (ft) Volume (cy) Unit Cost TOTALWet ConstructionStone 6A 5,684 1,785 18.00$ 32,138$Sand Class 2 5,684 2,171 5.50$ 11,943$Hauling (Bedding Material) 3,957 5.00$ 19,784$Haul Away Spoils 5,982 5.00$ 29,911$Dry ConstructionSand Class 2 22,736 15,827 5.50$ 87,050$Hauling (Bedding Material) 15,827 5.00$ 79,136$Haul Away Spoils 23,929 5.00$ 119,645$

SUB TOTAL 379,606$


P I P E S U B T O T A L 6,069,561$COST OF PIPE /ft 213.57$

SPECIALS Unit Cost TOTALBends 16 units 7,710$ 123,360$Air Release Valve Units 6 units 23,000$ 138,000$Isolation Valve Units 2 units 97,430$ 194,860$Blow-off Valve Unit 2 units 61,550$ 123,100$Flushing / Hydrant 2 units 2,000$ 4,000$SUB TOTAL 583,320$


OVERHEAD & PROFIT 15% 997,932$

G R A N D - T O T A L 7,650,813$

GENESEE COUNTY FINISHED WATER LINE



13/13

DESCRIPTION LENGTH COST/FT COST

LAKE HURON TRANSMISSION 203,280 $523.01 $106,318,393

NORTH TRANSMISSION 77,760 $416.63 $32,397,005

SOUTH TRANSMISSION 73,450 $441.31 $32,414,230

FLINT TRANSMISSION 74,560 $356.21 $26,559,299

GENESEE COUNTY FINISHED WATER LINE 28,420 $269.21 $7,650,813

S U B - T O T A L S 457,470 $448.86 $205,339,739

15% CONSTRUCTION CONTINGENCY $30,800,961

5% DESIGN CONTINGENCY $10,266,987

17% ENGINEERING, LEGAL, BOND & ADMINISTRATIVE $34,907,756

TOTAL CONSTRUCTION COST $281,315,443

COST SUMMARY

kwa - preliminary engineering report - sept 2009 - appendix 6

Documents