Bas i s o f Des ign Repo r t

Resource Recovery and Electrical Energy Project

Volume 1 of 2

Prepared for Green Bay Metropolitan Sewerage District

April 2013

Prepared by

III

Contents

Volume1

1. Introduction.........................................................................................................................................111.1 Background......................................................................................................................................111.2 PreviousStudies...............................................................................................................................111.3 ReportOutline/Format....................................................................................................................121.4 ProjectApproachtoDesign.............................................................................................................13

1.4.1 GBMSDIndustrialCustomersUpdatedFlowsandLoads...................................................131.4.2 AlternativeEvaluationsAddressedintheBODR................................................................131.4.3 InterimDeliverables...........................................................................................................14

1.5 ProjectApproachtoProcurement...................................................................................................141.6 ProposedApproachtoConstruction,Commissioning,andOperatorTraining...............................15

2. ProjectConstraints...............................................................................................................................212.1 Purpose............................................................................................................................................212.2 ProjectFundingLimits.....................................................................................................................212.3 Schedule..........................................................................................................................................212.4 RegulatoryandAgencyRequirements............................................................................................212.5 RiskManagement............................................................................................................................22

3. ExistingFacilities..................................................................................................................................313.1 GeneralDescription.........................................................................................................................313.2 Background......................................................................................................................................313.3 ExistingFacilitiesandInfrastructureAffectedbyR2E2...................................................................31

3.3.1 InfluentPumpStation.........................................................................................................323.3.2 PrimarySludgeandScumThickening.................................................................................323.3.3 SeptageReceiving...............................................................................................................323.3.4 ActivatedSludgeSystem....................................................................................................323.3.5 WasteActivatedSludgeSystem.........................................................................................343.3.6 SludgeDewatering..............................................................................................................343.3.7 IncinerationandAshHandling...........................................................................................34

3.4 ExistingInfrastructure.....................................................................................................................353.4.1 PlantHeatingSystem..........................................................................................................353.4.2 ElectricalSupplyandDistribution.......................................................................................363.4.3 SiteUtilities/TunnelSystem............................................................................................3123.4.4 StormwaterManagement................................................................................................3253.4.5 GroundTrafficPattern......................................................................................................326

3.5 ExistingNPDESPermits..................................................................................................................3263.6 AssetLifeExpectancy.....................................................................................................................329

3.6.1 Retain,Demolish,Modify,orReuse(fordifferentpurpose)............................................329

4. ProposedProcessFacilities..................................................................................................................414.1 GeneralDescriptionofNewFacilities..............................................................................................414.2 Flows,Loads,andSolidsBalance.....................................................................................................43

4.2.1 GeneralInformation...........................................................................................................434.2.2 KeyFindings........................................................................................................................434.2.3 GeneralSolidsProcessFlowDiagram.................................................................................444.2.4 FlowsandSolidsProduction...............................................................................................44

BASIS OF DESIGN REPORT

IV

4.2.5 UnitProcessEquipmentandDesignOperatingInformation.............................................454.3 PrimarySludgeThickeningandScumHandling...............................................................................49

4.3.1 Background.........................................................................................................................494.3.2 CothickeningUsingGravityBeltThickeners......................................................................494.3.3 ContinuedUseofGravityThickenersforPrimarySludgeThickening..............................4124.3.4 Recommendation.............................................................................................................414

4.4. SeptageandHighStrengthWasteReceiving................................................................................4154.4.1 Background.......................................................................................................................4154.4.2 ExistingFacilities...............................................................................................................4154.4.3 DesignCriteria..................................................................................................................4154.4.4 BuildingConfigurationAlternatives..................................................................................4184.4.5 ConstructionSequencing..................................................................................................4184.4.6 CostEstimate....................................................................................................................419

4.5 MesophilicAnaerobicDigestion....................................................................................................4214.5.1 ProcessAnalysis:DesignCriteria......................................................................................4214.5.2 ProcessFlowDiagram.......................................................................................................4284.5.3 MixingSystem...................................................................................................................4284.5.4 SolidsTransfer..................................................................................................................4314.5.5 HeatingSystem.................................................................................................................4324.5.6 DigestionEquipmentSummary........................................................................................4334.5.7 CostEstimate....................................................................................................................434

4.6 ChemicalFeedSystem...................................................................................................................4344.7 BiogasCleaning,Compression,Storage,andFlareSystems.........................................................436

4.7.1 BiogasManagementandStorage.....................................................................................4364.7.2 BiogasStorage..................................................................................................................4394.7.3 BiogasManagementandTreatment................................................................................4424.7.4 BiogasHandlingandStorageEquipmentSummary.........................................................4444.7.5 CostEstimate....................................................................................................................4444.7.6 References........................................................................................................................444

4.8 BiogasEngine/GeneratorSystem..................................................................................................4474.8.1 Background.......................................................................................................................4474.8.2 ExistingFacilities...............................................................................................................4474.8.3 DesignCriteria..................................................................................................................4474.8.4 RecommendedApproach.................................................................................................4484.8.5 Procurement.....................................................................................................................4514.8.6 DesignConsiderations......................................................................................................4514.8.7 ConstructionSequencing..................................................................................................4544.8.8 CostEstimate....................................................................................................................455

4.9 DewateringandDrying..................................................................................................................4574.9.1 Background.......................................................................................................................4574.9.2 ProcessDesignBasisandSummary..................................................................................4574.9.3 VaughanRotaMixHydraulicMixingSystem.....................................................................4584.9.4 CakeStorage.....................................................................................................................4674.9.5 FunctionalDesignConsiderations....................................................................................4724.9.6 CostEstimate....................................................................................................................474

4.10 PolymerMakedownandFeedSystem..........................................................................................4754.10.1 Background.......................................................................................................................4754.10.2 ExistingFacilities...............................................................................................................4754.10.3 DesignCriteria..................................................................................................................4754.10.4 PolymerTrialUnit.............................................................................................................4764.10.5 AlternativesEvaluated......................................................................................................477

CONTENTS

V

4.10.6 RecommendedApproach.................................................................................................4784.10.7 ControlPhilosophy...........................................................................................................4794.10.8 ConstructionSequencing..................................................................................................4804.10.9 CostEstimate....................................................................................................................4804.10.10EmulsionPolymerStorageTanks.....................................................................................4804.10.11FutureExpansion..............................................................................................................480

4.11 FluidBedIncinerationandWasteHeatRecoveryandAirPollutionControl...............................4814.11.1 Background.......................................................................................................................4814.11.2 ExistingFacilities...............................................................................................................4814.11.3 DesignCriteria..................................................................................................................4814.11.4 AlternativesEvaluated......................................................................................................4814.11.5 RecommendedApproach.................................................................................................4864.11.6 Procurement.....................................................................................................................4914.11.7 DesignConsiderations......................................................................................................4934.11.8 ControlPhilosophy...........................................................................................................4944.11.9 ConstructionSequencing................................................................................................41024.11.10CostEstimate..................................................................................................................4102

4.12 EnergyRecoveryandReuse.........................................................................................................41034.12.1 Background.....................................................................................................................41034.12.2 EnergyRecovery.............................................................................................................41034.12.3 HeatUtilization...............................................................................................................4104

4.13 AshThickening,Pumping,Dewatering,andConveyance............................................................41074.13.1 Background.....................................................................................................................41074.13.2 ExistingFacilities.............................................................................................................41074.13.3 DesignCriteria................................................................................................................41074.13.4 AlternativesEvaluated....................................................................................................41074.13.5 DesignConsiderations....................................................................................................41144.13.6 AshEquipmentControlPhilosophy................................................................................41154.13.7 Architectural...................................................................................................................41154.13.8 BuildingServicesandHeatingandVentilation...............................................................41164.13.9 CostEstimate..................................................................................................................41164.13.10Recommendation...........................................................................................................4116

4.14 ThickenedSludgePumping..........................................................................................................41174.14.3 BackgroundandExistingFacilities..................................................................................41174.14.4 DesignCriteria................................................................................................................41174.14.5 AlternativesEvaluated....................................................................................................41174.14.6 RecommendedApproach...............................................................................................41194.14.7 ProcessDesignSummary................................................................................................41194.14.8 Redundancy....................................................................................................................41204.14.9 DesignConsiderations....................................................................................................41204.14.10OperationandControlStrategy.....................................................................................41214.14.11ConstructionSequencing................................................................................................41214.14.12CostEstimate..................................................................................................................4121

4.15 ProcessSupportFacilities............................................................................................................41234.15.1 PlantServiceWaterSystem............................................................................................41234.15.2 CityWaterSystem..........................................................................................................41254.15.3 UtilityAirSystem............................................................................................................41264.15.4 NaturalGasSystem.........................................................................................................41264.15.5 FuelOilSystem...............................................................................................................4127

4.16 OdorControlSystem...................................................................................................................41294.16.1 Background.....................................................................................................................4129

BASIS OF DESIGN REPORT

VI

4.16.2 ExistingFacilities.............................................................................................................41294.16.3 OdorControlandVentilationGoals,VentilationRates,andSourcestoControl..........41294.16.4 DesignCriteriaandPerformanceRequirements............................................................41324.16.5 RecommendedApproach...............................................................................................41324.16.6 Ductwork........................................................................................................................41344.16.7 ConceptofOperation.....................................................................................................41344.16.8 InstrumentationandControls........................................................................................41354.16.9 OperationandMaintenance..........................................................................................41354.16.10CostEstimate..................................................................................................................4135

4.17 AirPermittingSectionofDesignBasis.........................................................................................41374.17.1 Background.....................................................................................................................41374.17.2 PermittingApproach......................................................................................................41374.17.3 CommunicationswithWDNR.........................................................................................41374.17.4 AirQualityIssuesToBeAddressed................................................................................4137

5. CostEstimating....................................................................................................................................515.1 CostEstimatePhilosophyandMarkups..........................................................................................515.2 Buildings...........................................................................................................................................515.3 Equipment.......................................................................................................................................515.4 PipingSystems.................................................................................................................................515.5 I&CandElectrical.............................................................................................................................525.6 Foundation.......................................................................................................................................525.7 Other................................................................................................................................................52

6. DisciplineConcepts..............................................................................................................................616.1 ConstructionContractandProcurementPlanning.........................................................................61

6.1.1 Background.........................................................................................................................616.1.2 DesignConsiderations........................................................................................................66

6.2 CivilDesignConcepts.......................................................................................................................696.2.1 BackgroundInformation.....................................................................................................696.2.2 SourcesofInformation.....................................................................................................6106.2.3 ExistingConditions............................................................................................................6106.2.4 DesignCriteria..................................................................................................................6106.2.5 SiteAccess........................................................................................................................6116.2.6 Landscaping......................................................................................................................6116.2.7 SiteGradingandErosionControl.....................................................................................6146.2.8 StormwaterControl..........................................................................................................6146.2.9 RecommendedDesign......................................................................................................6166.2.10 SurveyControlandRequirements....................................................................................6166.2.11 DemolitionDesignConcepts............................................................................................617

6.3 Architectural..................................................................................................................................6256.3.1 DesignCriteria..................................................................................................................6256.3.2 CodesandStandards........................................................................................................6256.3.3 BuildingSystemsandMaterials........................................................................................6256.3.4 Dewatering,Incineration,andCogenerationFacility.......................................................6276.3.5 SolidsProcessingBuilding.................................................................................................6306.3.6 DigesterControlBuilding..................................................................................................6306.3.7 HighStrengthWasteandSeptageReceivingFacility.......................................................6306.3.8 PrimarySwitchgearBuilding.............................................................................................630

6.4 Structural.......................................................................................................................................6306.4.1 ProjectStructuresandFacilities.......................................................................................6306.4.2 ExistingInformation..........................................................................................................633

CONTENTS

VII

6.4.3 Codes,Standards,andRegulations..................................................................................6336.4.4 References........................................................................................................................6336.4.5 DesignLoads.....................................................................................................................6336.4.6 GeotechnicalDesignParameters......................................................................................6356.4.7 StabilityCriteria................................................................................................................6356.4.8 DeflectionCriteria.............................................................................................................6356.4.9 VibrationDesignCriteria..................................................................................................6356.4.10 ProgressiveCollapseDesignCriteria................................................................................6356.4.11 StructuralSystemRequirements......................................................................................635

6.5 Geotechnical..................................................................................................................................6366.5.1 ProjectOverview..............................................................................................................6366.5.2 ScopeofGeotechnicalInvestigation................................................................................6366.5.3 MajorFindings..................................................................................................................637

6.6 BuildingServices............................................................................................................................6376.6.1 HVACSystemConcepts....................................................................................................6376.6.2 EnergyCodeComplianceandBuildingInsulation............................................................6396.6.3 HVACGeneralDesignCriteria...........................................................................................6396.6.4 HVACControl....................................................................................................................6446.6.5 SafetyAlarms....................................................................................................................6446.6.6 PlumbingSystems.............................................................................................................644

6.7 FireProtectionSystems.................................................................................................................6476.7.1 CodesandStandards........................................................................................................6476.7.2 FireProtectionSystemConceptsIfRequiredbyBuildingCode.......................................6476.7.3 PipingMaterials................................................................................................................6476.7.4 Design,Layout,andInstallation.......................................................................................647

6.8 ElectricalDesignConcepts.............................................................................................................6486.8.1 ExistingElectricalFacilities...............................................................................................6486.8.2 NewPowerDistributionFacilities....................................................................................6506.8.3 OnsiteElectricalPowerGeneration..................................................................................6526.8.4 OperatingStrategy............................................................................................................6536.8.5 ArcFlashStudy.................................................................................................................6536.8.6 BuildingbyBuildingElectricalApproach..........................................................................656

6.9 InstrumentationandControlConcepts.........................................................................................6576.9.1 General.............................................................................................................................6576.9.2 SystemArchitecture.........................................................................................................6586.9.3 Multiple,InterconnectedCommunicationNetworks.......................................................6586.9.4 ManualOverrideCapability..............................................................................................6596.9.5 MonitoringGuidelines......................................................................................................6596.9.6 ProcessControlFunctionalGuidelines.............................................................................660

6.10 SecurityDesignConcepts..............................................................................................................6606.10.1 BackgroundandExistingConditions................................................................................6606.10.2 ExistingConditions............................................................................................................6606.10.3 DesignIntent....................................................................................................................661

BASIS OF DESIGN REPORT

VIII

Volume2

Appendixes

A TechnicalMemorandumsCodigestionDewateringandDryingPolymerSystemWaterUsageEnergyRecoveryandHeatUtilizationOptionsOdorControlSystemSolarPhotovoltaicPreliminaryDesignandAnalysisUpdateFlowsandLoadsImpactofRecyclesandLossofIndustrialLoadsonGBFLiquidTreatmentProcessesCakeSolidsStorageAnalysisCombinedCycleEnergyRecoverySystemComparisonofAlternativeTankShapesforAnaerobicDigestion

B ConstructionCostEstimateC StudiesandReports LEED/SustainabilityManual GeotechnicalReportandFoundationDesignReport EquipmentNotebook[includingEquipmentListandDesignDataSheets][forthcoming] OperationsandMaintenanceIssuesandConcernsList[forthcoming] ArcFlashStudy[forthcoming] ProcessSafetyAnalysisReport[forthcoming]D Manuals[forthcoming] DesignProcessManual ProjectManual ElectricalDesignManual ConstructionManual InstrumentationandControlDesignManual EnergyMonitoringManual EmergencyPowerManual ProcessSafetyAnalysisManual

Tables

31 GBFInfluentPumpStationEquipmentandCapacities................................................................................3232 GBFPrimarySludgeandScumThickeningEquipmentandCapacities........................................................3333 GBFActivatedSludgeSystemEquipmentandCapacities............................................................................3334 WasteActivatedSludgeSystemEquipmentandCapacities........................................................................3435 SludgeDewateringSystemEquipmentandCapacities................................................................................3536 GBFIncinerationandAshHandlingSystemEquipmentandCapacities.......................................................3537 ExistingPrimaryHeatLoopRecirculationPumpDesignCriteria..................................................................3538 ExistingGBFTunnels...................................................................................................................................31639 ServiceWaterPumpDesignCriteria...........................................................................................................322310 SprayWaterPumpDesignCriteria.............................................................................................................3234.21 2035FacilityPlanandR2E2BasisofDesignThickenedWASandPrimarySludgeLoadingstoSolids

Processing.....................................................................................................................................................434.22 2017SolidsBalance......................................................................................................................................444.23 2035SolidsBalance......................................................................................................................................454.31 GravityBeltThickeningSystem..................................................................................................................4104.32 CothickeningDesignCriteriaforGravityBeltThickeners.........................................................................411

CONTENTS

IX

4.33 EquipmentRedundancySummary.............................................................................................................4124.34 CostEstimateforCoThickeningUsingGravityThickenerswithSeparationofScumattheSource.........4124.35 CostEstimateforContinuedUseofGravityThickenersforPrimarySludgeThickening...........................4134.41 SeptageScreening,Washing,andCompactionEquipmentDesignCriteria...............................................4164.42 HighStrengthWasteStorageDesignCriteria............................................................................................4174.43 HighStrengthWasteStorageTransferPumpDesignCriteria....................................................................4174.44 HSWIsolationStorageDesignCriteria........................................................................................................4184.45 HSWIsolationTransferPumpDesignCriteria............................................................................................4184.51 SiloShapedTankDimensions.....................................................................................................................4214.52 ProcessCalculationsforWAS,PS,andCodigestate..................................................................................4214.53 ProcessCalculations:ResultsandComparisonofDigestionwithandwithoutCodigestate....................4234.54 TypicalandNewValuesforCHRMADSystems.........................................................................................4244.55 MesophilicAnaerobicDigestionParametersforVariousSubstrates,........................................................4254.56 GBFBiogasProjections...............................................................................................................................4264.57 AnaerobicDigestionEquipment.................................................................................................................4344.58 AnaerobicDigestionSystemCostEstimate................................................................................................4344.61 ChemicalFeedSystemCostEstimate.........................................................................................................4364.71 BiogasHandlingandStorageEquipment...................................................................................................4444.72 BiogasHandlingSystemCostEstimate.......................................................................................................4454.81 ContaminantConcentrationsinBiogas......................................................................................................4474.82 ResultsofPreliminaryBiogasBenchScaleTesting....................................................................................4484.83 Engine/GeneratorDesignCriteriaandPerformance..................................................................................4494.84 PowerGenerationScenarios......................................................................................................................4504.85 ElectricalClassification...............................................................................................................................4534.91 SolidsProcessingBuildingCentrifugeFeedTankMixingSystemsDesignCriteria.....................................4584.92 CentrifugeFeedPumpsCapacityCalculations...........................................................................................4624.93 ExistingSolidsProcessingBuildingCentrifugeFeedPumpsDesignCriteria..............................................4624.94 ExistingSolidsProcessingBuildingDigestedBiosolidsGrinderDesignCriteria.........................................4634.95 CentrifugeDesignCriteria...........................................................................................................................4634.96 CentrateProduction...................................................................................................................................4644.97 CentrifugeCakePumpDesignCriteria........................................................................................................4654.98 DryerDesignCriteria...................................................................................................................................4664.99 IncineratorFeedPumpScrewConveyorDesignCriteria............................................................................4674.910 IncineratorFeedPumpDesignCriteria.......................................................................................................4684.911 ElectricalClassification...............................................................................................................................4744.101 ThickeningPolymerSystemDesignCriteria...............................................................................................4764.102 DewateringPolymerSystemDesignCriteria..............................................................................................4774.111 FBISystemDesignCriteria..........................................................................................................................4814.112 BiosolidsProcessingPerformanceRequirements......................................................................................4824.113 ComparisonofAuxiliaryComponents........................................................................................................4854.114 FluidBedReactor........................................................................................................................................4864.115 ThermalOilHeatExchanger.......................................................................................................................4874.116 SNCRSystem...............................................................................................................................................4874.117 WetScrubber..............................................................................................................................................4884.118 WetElectrostaticPrecipitator....................................................................................................................4884.119 CarbonAdsorptionSystem.........................................................................................................................4884.1110Stacks..........................................................................................................................................................4894.1111PreheatBurner...........................................................................................................................................4894.1112FluidizingAirBlowers..................................................................................................................................4894.1113IDFan..........................................................................................................................................................4894.1114PurgeAirBlowers.......................................................................................................................................489

BASIS OF DESIGN REPORT

X

4.1115SandSystem................................................................................................................................................4904.1116ReactorRoofSprayPumps.........................................................................................................................4904.1117CompressedAirSystem..............................................................................................................................4904.1118ScrubberChemicalSystem.........................................................................................................................4904.1119ThermalOilSystem.....................................................................................................................................4914.1120ThermalOilCooler......................................................................................................................................4914.1121FluidBedIncineration:ProcessWaterDemands.......................................................................................4924.1122FluidBedIncineration:WastewaterStreams.............................................................................................4924.1123FluidBedIncinerationSystemOperatingSchedule...................................................................................4964.131 AshProduction.........................................................................................................................................41074.132 AshDewateringMethods.........................................................................................................................41084.133 Alternative1AshSystemPipingMaterialsAlternatives..........................................................................41104.134 Alternative1EquipmentRedundancySummary.....................................................................................41114.135 Alternative1AshHandlingSystem...........................................................................................................41114.136 Alternative1AshRecycleStreamSummary.............................................................................................41124.12.7 Alternative2EquipmentRedundancySummary.....................................................................................41134.138 Alternative2AshHandlingSystem...........................................................................................................41144.139 AshRecycleStreamSummary..................................................................................................................41144.1310CostSummary...........................................................................................................................................41164.141 ThickenedSludgeProduction:2035.........................................................................................................41174.142 ThickenedSludgePumpOperatingScenarios..........................................................................................41204.143 ThickenedSludgePumpOperatingConditions........................................................................................41204.144 EquipmentRedundancySummary...........................................................................................................41214.145 CostEstimateforReplacingTWASPumpsandPiping..............................................................................41214.151 CurrentServiceWaterDemandstobeEliminated:SolidsProcessingBuilding......................................41234.152 ProjectedNewServiceWaterDemands:R2E2SolidsProcessing...........................................................41234.153 CurrentPlantEffluentWaterDemands:SolidsProcessing......................................................................41244.154 ProjectedNewPlantEffluentWaterDemands:R2E2SolidsProcessing..................................................41254.155 CurrentPoWaterDemands,SolidsProcessing.........................................................................................41254.156 ProjectedNewPoWaterDemands:R2E2.................................................................................................41254.161 OdorControlAirFlows.............................................................................................................................41304.162 OdorControlDesignCriteria....................................................................................................................41324.163 OdorControlPerformanceRequirements...............................................................................................41324.164 OdorControlEquipment..........................................................................................................................413361 DesignParameters:AlternativeC...............................................................................................................61562 DesignParameters:AlternativeD..............................................................................................................61663 NonprocessSpaceNeeds............................................................................................................................628

Figures

31 GBFNaturalGasUsage.................................................................................................................................3632 LocationofProposedR2E2Facilities............................................................................................................3933 GBFAverageMonthlyPotableWaterConsumption..................................................................................31334 LocationsofExistingGBFTunnels..............................................................................................................31735 CrossSectionsofTunnelsJandR...............................................................................................................31936 GroundTrafficPatternsattheGBF............................................................................................................3274.21 SolidsProcessFlowDiagram........................................................................................................................474.51 ProcessFlowDiagramoftheGBFCHRMADSystem.................................................................................4294.52 AnaerobicDigesterDrafttubeHydraulicMixingSystem...........................................................................4314.61 BiogasSystemProcessFlowDiagram.........................................................................................................4374.71 FixedCoverTypeF......................................................................................................................................4394.72 LiquidSealLaunderforFixedCover...........................................................................................................439

CONTENTS

XI

4.73 PressureVessels.........................................................................................................................................4404.74 ImageofRadialBeamStructureGasCoveronDigesters...........................................................................4404.75 MembraneHolder......................................................................................................................................4414.76 BiogasDrawoffFoamTrapAssembly.........................................................................................................4434.93 VaughanFoambusterNozzleinAction.......................................................................................................4614.94 VaughanFoambusterNozzleSprayTrajectory...........................................................................................4614.95 JetMixRotatableNozzle.............................................................................................................................4614.96 InteriorofSolidsOffLoadingBuildingatGBF:CakeSolidsStorageArea,PushWalls,andDistribution

Conveyor.....................................................................................................................................................4694.97 TypicalScrewConveyorCakeDistributionSystem.....................................................................................4694.98 TelescopicTroughedConveyor...................................................................................................................4704.111 ConditionsforAutogenousIncineration....................................................................................................4834.161 BiotricklingFilter.......................................................................................................................................41334.162 CarbonFilter.............................................................................................................................................41334.163 BiotricklingFiltersandCarbonVesselLocation........................................................................................413461 NoMowGrass............................................................................................................................................61262 NativeGrassesandWildflowers.................................................................................................................613

1. Introduction and Background

1. Introduction

1.1 Background GBMSDs mission is to establish a regional Solids Management Plan using a sustainable approach for energy, air, and solids within the social, environmental, and economical values of our customers and stakeholders. The Resource Recovery and Electrical Energy Project (R2E2) will replace the aging solids facilities at the Green Bay Facility (GBF) to provide solids capacity for current and future loads while meeting new air pollution regulations. The project will reduce fossil fuel consumption significantly, saving GBMSD millions of dollars over the life of the project, by providing sustainable facilities that minimize the use of resources and impacts on the environment.

The existing solids handling facilities are challenged by the following:

Aging equipment at the end of its useful life, requiring increasing operation and maintenance but with decreasing reliability

Pending Maximum Achievable Control Technology (MACT) air pollution regulations that the existing incineration controls cannot meet

A system at full capacity because of the addition of sludge from the De Pere Facility (DPF).

The R2E2 Project will provide anaerobic digestion of waste activated and primary sludges, followed by dewatering and then incineration. These processes will generate and recover significant energy. Engines powered by biogas from the digesters will generate electricity, and heat recovered from the engines and incineration will be used to dry the dewatered sludge to an autogenous1 consistency, generate power, heat plant buildings, and heat the digester process.

1.2 Previous Studies Between 2008 and 2011, CH2M HILL collaborated with GBMSD on a solids management facility plan that evaluated solids processing technologies and process trains to respond to the challenging issues above. Six alternatives were selected and evaluated in detail. GBMSD selected Alternative 3B, Digestion with Thermal Processing and Electrical Generation, later named the Resource Recovery and Electrical Energy Project, or R2E2. After this Basis of Design Report is completed and revisions are made as a result of the proposed value engineering exercise, the Solids Management Facility Plan will be updated and resubmitted to the appropriate regulatory agencies.

The following reports were available and were reviewed:

1971 (STS Job 3955A): Geotechnical Report for Original GBF Construction 1983 (STS Job 12311): Geotechnical Report for Solids Processing Building Addition (never constructed) 2007 (STS Job 200704881): Geotechnical Report for 2009 Diesel Generator Project

Based on information in these reports, our experience, and the design of existing structures, we can anticipate the foundation types of the proposed new structures. Single-story buildings with basements, such as the Digester Control Co-digestion buildings, likely will be on mat foundations. Multi-story buildings with basements, such as the Solids Processing buildings, likely will be on mat foundations or individual column footings, depending on the type and configuration of building designed. The circular tanks (Digesters, Biogas Storage, and Sludge Holding tanks) are also expected to be on mat foundations.

The Short-Circuit, Protective Coordination and Arc Flash Study (for GBF electrical distribution system) by High Voltage Maintenance Corp. (2008) was reviewed. After that study was completed, the diesel engine generator project was constructed. Electrical coordination of new components and devices for the engine generators was

1 "Autogenous burning" is the condition under which burning occurs without the addition of supplemental fuel. (R. Shipley Jr., Calvin Bruner, and Gregory M. Parker. Incineration of Hot Sludge.)

1-1

BASIS OF DESIGN REPORT

performed as a part of that project, and GBMSD provided this documentation to the project team. The electrical study and background information provided by GBMSD have provided a sound basis for the design, for performing the current Arc Flash Study, for coordinating and recommending protective device settings, and for specifying electrical equipment PPE labeling requirements for the R2E2 project.

1.3 Report Outline/Format This Basis of Design Report (BODR) establishes and documents the requirements and constraints for the multiple tasks and project components. The BODR defines all design aspects including the following:

Overall project delivery goals and approach for each phase, including design, prequalification of contractors, subcontractors, and system houses, bidding, equipment procurement, construction, and startup

Flows/loads and solids balances

Approach to setting design criteria and establishing appropriate inputs

Zoning, planning, and other local regulations

Project funding limits

Project delivery approach, as covered in the Project Delivery Guide

Confirmed design level of detail planned for the deliverables under each phase

Construction cost estimates

Confirmed design and construction contract packaging

Bidding and procurement requirements and any sole-sourcing requirements

Confirmed list of owner-furnished, prepurchased, prenegotiated, or preselected equipment

Critical need dates and required lead time to obtain prepurchased equipment

Control system design approach and SCADA architecture

Documentation of existing site conditions

Use of and connection to existing buildings and structures

Use of and connection to existing services/utilities and tunnels

Site traffic access impacts and improvements

Confirmation of solids processing requirements and major equipment types and sizes, as described in the facilities plan

Define surveying needs

List of applicable codes and required permits along with a proposed schedule for filing permit requests

Establish a list of controlling regulatory agencies and contacts for reviews and submittals

Process flow diagrams and narratives

Process and instrumentation diagrams

Preliminary equipment list and design data sheets for major equipment

Preliminary site plans, site finishing, and stormwater management

Preliminary building floor plans showing rooms and major equipment

Preliminary building elevations

1-2

1. INTRODUCTION

Preliminary control system block diagram sketch, including control philosophy

Control system architecture, and methods for integration with existing systems

Structural design concepts

Architectural design concepts including opportunity for LEEDS Silver certification

Geotechnical report and final foundation design recommendations

HVAC, plumbing, and fire protection design concepts and code adherence

Electrical, communications, and security design technologies and approach

The BODR contains the following main sections:

1. Introduction (including background, project goals, and design and procurement approaches) 2. Project Constraints (including funding limits and regulatory milestones) 3. Existing Facilities (being replaced in kind, upgraded, or superseded, including asset life expectancy) 4. Proposed Process Facilities (including projected design life expectancy) 5. Approvals and Permits 6. Cost Estimates 7. Discipline Concepts 8. Technical memorandums

Each proposed process facility section typically has the following standard contents:

Design basis, including process capacity rating and redundancy

Evaluation of alternative sizes and configurations

Process design summary, including process flow diagram, location onsite and associated traffic pattern, mass balance, and recycle streams as applicable

Control philosophy for automatic and manual operation

Recommended alarm conditions and action to be taken

Design considerations and recommendations, including references to drawings included elsewhere in the BODR, sampling requirements, implementation schedule and sequence, applicable codes and standards, LEEDS aspects, and provisions for future expansion as applicable.

Cost estimates that ultimately are rolled up in the cost estimate section

1.4 Project Approach to Design 1.4.1 GBMSD Industrial Customers Updated Flows and Loads Previously documented industrial flows and loads updated to current and future projected loads and flows Impact (if any) of updated flows and loads on facility plan

1.4.2 Alternative Evaluations Addressed in the BODR Evaluations of digestion shape configuration, mixing, and heating equipment types; digester gas conditioning

equipment; cogeneration heat energy recovery and reuse configuration; incineration heat recovery and reuse configuration: incinerator ash dewatering approach; gas storage vessels type; biosolids dewatering equipment type; biosolids thickening and pumping equipment type; dewatered biosolids conveyance equipment type.

Evaluations of appropriate biowastes to compliment codigestion.

Evaluations of digester design criteria using bench-scale pilot tests with and without industrial wastes.

1-3

BASIS OF DESIGN REPORT

1.4.3 Interim Deliverables Interim deliverables included early technical training for GBMSD staff, including operations and maintenance personnel, and technical memorandums configured to solicit input from GBMSD staff before finalizing recommendations for equipment selection, sizing and configuration, and location onsite. This was accomplished by the following:

Direct GBMSD staff feedback used to create a list of issues and concerns Workshops to discuss process selection/recommendations proposed by the design team Presentations made to and accepted by the ZERO DELTA committee

A list of concerns and issues was solicited from the operations and maintenance staff. Concerns and issues were addressed and approaches highlighted in the finalization of each section before the finalization of the BODR deliverable.

When all decisions have been made, the draft BODR was prepared for the value engineering review. After the value engineering exercise, all value engineering recommendations accepted by GBMSD will be incorporated into the final BODR. When approved by GBMSD, the design set forth in the BODR will be frozen so that detailed design can proceed, without concept revisions, to prepare contract bid documentation.

1.5 Project Approach to Procurement Procurement can affect progress schedule and required coordination of various contracts. It can be segregated into the following types of procurement:

GBMSD prepurchases equipment before the completion of design.

Equipment is preselected, and the general contractor is compelled to purchase that preselected equipment.

Equipment vendors are prequalified, and the general contractor is compelled to purchase and name the selected manufacturer from a list of prequalified manufacturers.

Equipment of multiple alternate manufacturers is specified, and general contractor is allowed to purchase from one of named alternates.

Contractors, major subcontractors, and system houses are prequalified.

Equipment prepurchase or preselection typically is used when various alternates have different configurations that may lead to some issues during construction if the design was based on another of the acceptable alternates. For example, centrifuges are supplied in both concurrent and countercurrent flow patterns. This means completely different design piping configurations and may affect the conveyance arrangement for the dewatered product. Westphalia feeds from the centrate discharge end of main shaft, and Alfa Laval feeds from the dewatered cake discharge end of main shaft.

Locally manufactured equipment (that is, in Wisconsin) can be promoted by allowing evaluation of submittals, instead of leaving the evaluation up to the general contractor.

Prequalification typically is used to exclude marginal performing equipment from being considered by a general contractor and offered as an alternate requiring significant schedule delay to conduct an assessment that is beyond reproach before contract award. This may cause breach of the bid validity period. For example, in the field of cogeneration equipment, the Advanced Reciprocating Engines Systems program sponsored by U.S. Department of Energy stated:

With reciprocating engines offering the highest potential for improvement, DOE initiated and established the ARES program for DG applications. The goal of this program is to lead a national effort to design, develop, test and demonstrate a new generation of reciprocating engine systems for DG applications that are cleaner, more affordable, reliable and efficient than products that are commercially available today. The program goals include Engine Electrical Efficiency > 50%, NOx: < 0.1 g/hp.hr, Fuel Flexibility, Cost of Power to be 10% less than

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1. INTRODUCTION

current systems, and Availability, Reliability, and Maintainability equivalent to current state-of-the-art systems.2

Some advancements have been adopted and are being marketed by some engine manufacturers for various sizes of engines, but some other manufacturers are not yet ready to market their developments. So that only the highest efficiency engines are considered, once engine size is selected it may be desirable to prequalify only those manufacturers that have the recommended cogeneration electrical output efficiency in the size range.

Prequalification of general contractors, major subcontractors, and system houses will be considered where the work is of a specialty nature and the confidence level in performance needs to be as high as possible. This approach will be reserved for contracts that warrant such limitations. Recognizing that prequalification can be extensive, recommendations on when to use such approaches will be made at the 60 percent completion of design after consultation with GBMSD.

1.6 Proposed Approach to Construction, Commissioning, and Operator Training

Engineering services during construction are not part of this assignment. We recommend that approaches for such activity be discussed when the GBMSD decides on service provider.

2 Quoted from Argonne systems laboratory press release. March 2010. 1-5

2. Project Constraints

21

2. Project Constraints 2.1 Purpose Thissectiondefinesthefundinglimits,andestablishestheprojectscheduleforthedesignphasesoastomeetthedateforcompliancewiththenewIncinerationMACTstandards,asdeterminedbytheWisconsinDNR.ItalsocontainstheR2E2teamriskmanagementfindings.

2.2 Project Funding Limits TheSolidsManagementFacilityPlanselectedAlternative3B,DigestionwithThermalProcessingandElectricalGeneration,laternamedtheResourceRecoveryandElectricalEnergyProject,orR2E2.ThefacilityplanconstructionestimateforAlternative3Bwas$125,000,000(2011$).AprerequisiteoftheR2E2project,asapprovedbytheGBMSDCommission,wasthatthetotalprojectconstructioncostnotexceedthetotalcapitalcostof$147,000,000(2011$).Thatcostceilingincludesconstructioncosts,totalengineeringfordesignandconstruction,andGBMSDadministrativecosts.

2.3 Schedule TheschedulefortheBasisofDesignReport(BODR)establishesanddocumentstherequirementsandconstraintsforthemultipletasksandprojectcomponents.Itdefinesallaspectsofdesign,includingtheoverallprojectdeliverymilestonesforeachphase:predesign,design,prequalificationofcontractors,subcontractors,andsystemhouses,bidding,equipmentprocurement,construction,andstartup.

AttachmentAcontainsthedetailedschedule.Thebaselineschedulepresentsthestartandfinishdatesofeachdeliverableandtaskachievement.Eachtaskcommenceswithataskdeliverableoutlineortableofcontents,followedbyaneditorialandQCcheckofeachdraftdocument.Thedeliverablesarethenissuedforclientreview(IFCR)bypostingontheprojectSharePointsiteandnotifyingGBMSDsprojectmanager.GBMSDhasanaverage10workingdaysforreviewcommentstobecompiledandreturnedtoCH2MHILL.

Feedbacktypicallyisdiscussedinaworkshopscenario,withkeystafffromGBMSDandthedesignteam,includingtechnicalexperts.Followingtheworkshop,CH2MHILLwillincorporaterevisionsagreedtointheworkshopandallowsGBMSDtovalidatethedeliverablebeforeitisissuedfordesign(IFD)andbecomespartofthefinalBODR.Inthecaseofotherdeliverables,suchasthosefortraining,theschedulewillliststhestartandfinishofthetypicaleventsforeachtrainingmodule.

TheschedulefortechnicalaspectsworkshopswasdevelopedtoensurethattrainingwascompletedbeforeGBMSDsreviewandbeforetechnicalworkshopsonthenewunitprocessescommenced.ThepurposewastoensuremeaningfulparticipationandfeedbackfrombothGBMSDengineeringandplantpersonnel.

CH2MHILLalsopreparedacashflowpredictionfortheentireprojectincludingconstruction.Initiallysomebasicassumptionsweremaderegardingequipmentprepurchaseandthemainconstructionworkpackagepaymentterms.

Boththebaselinescheduleandthecashflowpredictionwillbeupdatedatmajordesignphasecompletionsandalsoevery6months.Asprogressreviewsidentifyactivitiesthatmustprecedeoraredependentonothers,suchadditionstoschedulelogicwillbeintegratedintothescheduleasisappropriate.Ifdeliverablesarelate,adjustmentstofloatwillbemadeasfeasible.Whenalmostallfloatisconsumed,werecommendthatmitigationmeasuresbeinstitutedtoavoidimpacttothekeymilestonesfortheBODRand30,60,and100percentdetaileddesign.

2.4 Regulatory and Agency Requirements TheR2E2projectissubjecttothefollowingregulationssetbyfederal,state,andlocalagencies.ApplicablesectionsoftheBODRcontainmoreinformationregardingtheregulations.

BASIS OF DESIGN REPORT

Air Regulations NR 445Control of Hazardous Pollutants (Wisconsin Administrative Code)

40 CFR 60, Subpart JJJJStandards of Performance for Stationary Spark Ignition Internal Combustion Engines (Code of Federal Regulations)

40 CFR 63, Subpart ZZZZNational Emissino Standards for Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines (Code of Federal Regulations)

Asbestos Removal Regulations (from Demolished Buildings) NR 447Control of Asbestos Emissions (Wisconsin Administrative Code)

Storm Water Regulations Chapter 30Storm Water Management (City of Green Bay Ordinances)

Chapter 34Construction Site Erosion Control (City of Green Bay Ordinances)

NR 151Runoff Management (Wisconsin Administrative Code)

NR 216Storm Water Discharge Permits (Wisconsin Administrative Code)

Facility Design Regulations NR 110Sewerage Systems (Wisconsin Administrative Code)

Oil Spill Control Regulations 40 CFR 112Oil Pollution Prevention (Code of Federal Regulations)

2.5 Risk Management The R2E2 design team prepared a Risk Management Manual and conducted a Risk Management workshop. The manual and the output from the workshop are contained in Appendix D. In the workshop the following approach was used to develop the Risk Register.

The R2E2 team undertook the following activities in accordance with the Risk Management manual:

Identified risks through a workshopThe baseline tool was seeded with risks identified in the chartering session and other discussions. A focused risk management workshop was conducted to establish a thorough initial risk register.

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2. PROJECT CONSTRAINTS

Establish likelihood and consequenceAt the risk management workshop, anticipated risks were brainstormed and consensus reached on validity of that initial listing. Each validated risk was given a specific ranking of likelihood of occurrence and severity of consequence, allowing prioritization of low, medium and high risk areas.

Establish mitigation plans and assign ownershipA mitigation strategy was proposed and responsibility was assigned to flesh out the mitigation plans. Updates of the status of risk, its mitigation, were integrated into the design phase work plan to be undertaken at the key milestones of : Postvalue engineering update of the BODR 30% design/constructability review 60% design/constructability review 90% design/constructability review Preconstruction Precommissioning

Manage risk through monthly reassessment of priorities and actionsThe risk register will be included as part of the monthly report and will be updated from time to time, with thorough review at key project milestones listed above.

Conduct constructability reviewsAs construction and procurement packages are defined, constructability reviews will be initiated. The risk register will be used to assist in the constructability reviews. It will be updated based on the findings of the reviews and measures taken in contract packaging to mitigate risk.

Conduct a value analysisAs a part of the risk review process, the value of mitigating risk will be identified. That value can be compared with cost to determine whether mitigation efforts for a specific risk are worthwhile.

Estimate the probable costAs mitigation measures are identified, estimates will be made of the costs associated with those measures. Costs will be considered in light of the value of the mitigation and be considered in the Zero Delta review process.

The project Risk Register was compiled as a result of the risk management workshop with CH2M HILL design team leaders and GBMSD oversight team. (The Risk and Value Management Guide can be found in the Appendix D). The project manager and project engineer will maintain and update the register after each major milestone (BODR and 30, 60, and 100 percent detailed design). The register records all identified risks, their likelihood, impact severity, person responsible for implementing and monitoring recommended mitigation measures. See attachment A for the current Risk Register.

The following are high risks and proposed mitigation strategy and current results.

Risk # Risk Description Undesirable Consequence RCM Ranking Update

4 Underestimate availability of high- strength wastes

Undersized facilities Provide space for expansion of Anaerobic Digestion.

Space provided

5 Delay in air permit Delay in construction start Comprehensive bimonthly meetings with DNR. Under way

6 MACT compliance date fixed

Sludge cake to landfill Comprehensive bimonthly meetings with DNR. Underway

9 Lack of consultant resources

Project predesign and design delay

Monitor schedule/find resources. Adequate re-sources assigned

18 Interruption of plant operations during construction

Potential permit violations, delay claims, fines, personnel safety threats

Interview operators for concerns during design. Provide effective training for operators (new processes).

Included in work plan

21 Hazard analysis Injury or property damage Provide competent facilitator for HAZOP workshop. Include key GBMSD staff.

Planned for after 60% review

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BASIS OF DESIGN REPORT

Risk # Risk Description Undesirable Consequence RCM Ranking Update

45 Subsurface conditions different

Change orders Undertake a comprehensive subsurface investigation.

Completed February 2013

46 Site coordination Traffic issues and concerns Communicate to contractor in bid documents. Planned

48 Unit operations compromised

Release of partially treated sewage, permit violation, equipment replacement

Specifications to mitigate risk. Planned

49 Hazardous material releases

Oil spill; release of untreated sewage, asbestos, lead, mercury

Undertake a hazardous materials assessment and prepare specifications to mitigate risk.

Planned for design phase

The following are medium risks and proposed mitigation strategy and current results.

Risk # Risk Description Undesirable Consequence RCM Ranking Update

1 Overestimate of GBMSD industrial waste flows

Facilities oversized Review rate structure to consider industrial user incentives or more favorable rates.

GBMSD preparing rates

3 Overestimate of high-strength industrial waste flows (trucked in)

Facilities oversized Obtain agreements or MOUs from generators/haulers, modularize and design with lower limits.

GBMSD to consider

7 Public opposition to incinerator

Stop the project or have negative public image

Continued stakeholder interfaces. GBMSD to maintain contact

8 Lack of available GBMSD resources to make decisions

Delay project design and add design cost

Delegate, schedule and manage review process.

GBMSD to manage

10 Buy American require-ments of funding or loan

Additional work and cost Establish plan and develop level of effort estimate.

Planned

11 Electrical generation units incompatible with WPS

Inability to export power to grid or claim RECs, delays in com-missioning, sync and trip issues

Coordinate with WPS and design facili-ties in accordance with requirements, consider in arc flash and coordination studies.

Planned

13 Scope creep Additional cost and schedule added

Identify all cost and schedule related change. Assess with ZERO DELTA.

Get ZERO DELTA up and running

14 Aesthetics Noise, dust, odors, public complaints, public perception

Use attractive skin finishing and architectural massing.

Planned

16 Underestimation of construction cost

Reduce scope, cancel contract (items) or go back to rate payers

Provide for additive alternatives in bid documents.

Planned

19 Stakeholders actively resisting R2E2

Project delay, changes or cancellation

Continued interface and rate structure review.

GBMSD to manage

20 I&C not robust Operational risk and added O&M costs

I&C design manual and design to be vetted by GBMSDs I&C staff.

Planned

22 R2E2 power redundancy

Single point of failure Assure full redundancy of utility feed in design.

Planned

23 Uninterrupted power for critical processes

Losing critical unit process, endangering public H&S, permit violation

Assure uninterrupted power supply to critical functions in design.

Planned

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2. PROJECT CONSTRAINTS

Risk # Risk Description Undesirable Consequence RCM Ranking Update

24 Cash flow not as anticipated

Require unexpected bond or loan activity, affecting rating and rates

Monitor and alert on any significant cash flow changes to the 2-year planning, develop work around strategies for deviation.

Planned

25 Use gravity belt thickeners to thicken primary sludge in lieu of rehabbing them

Rehabbing gravity thickeners may be unnecessary; no need to cover gravity thickeners; can reuse gravity thickeners for other purposes

Investigate sludge heating and other strategies for sludge thickening in GBTs.

Investigation indicated use GBTs

27 Reuse Solids Building basement boiler

How to incorporate new heating system into existing, one boiler retubed in summer 2007

Investigate basement boiler continued use suitability and basement use in general.

Planning to use boiler

28 Replace diesel with dual fuel natural gas/biogas generators

The diesel generators have resale value; may be less expensive to generate own power by burning natural gas, air permitting issues may impact this opportunity

Consider emergency generation in design of dual fuel engine generators, that could eliminate one or both emergency generators.

Investigation indicated that gas fired engines are not as good as diesel for emergency service

29 Dewatering equipment producing dryer cake than anticipated in the Facility Plan

Assures autogenous incineration, provides more efficient combustion, and avoids capital costs

Investigate dewatering equipment and dryer options and operations history.

Visit to operating facilities resulted in selecting a dryer with dewatering

30 Alternative uses of waste heat

Investigate energy use for preheating sludge and polymer solution before dewatering, and using an adsorption chiller

Review energy balance to maximize waste heat capture and minimize capital costs.

TN proposed multiple uses of recoverable waste heat

31 Recirculate centrate back to dewatering process

Reduce centrate load to plant, need to filter the centrate, use less city water and take advantage of residual polymer in centrate

Evaluate recirculation as part of equipment options and selection.

Modeling indicated not necessary to reduce centrate load back to plant

32 New technology may not perform as expected

Negative impact to entire solids handling system if one part does not perform as expected

Evaluate all critical components to ensure cost-effective redundancy.

Undertook pilot tests for critical processes: diges-tion, codigestion, dewater-ing samples from same

33 Conducting PSD review Evaluate controlling emissions from each type of equipment, delay to project

Meetings and review with designers and DNR to assure we do not require PSD permitting.

Planned

34 Change in mill loading Mill pulls out of liquid treatment side and GBMSD receives mill solids to treat

Assess rate structure; provide rates that reflect costs and benefits associated with different waste streams.

GBMSD to manage

35 End use of ash Recategorized as nonhazardous solid waste

Assess likely ash composition and any variance from existing ash.

Planned

36 End use of ash Avoid land-filling costs Investigate beneficial use (and/or lower cost disposal) options of ash.

Can use to restore plant site areas

37 Utility rates increase faster than assumed

Energy costs higher, operating budget issue

Meetings with utility to understand risk. Planned

38 Major equipment not operating as intended or specified

Unit process failure leading to replacement costs, operations costs and permit violations

Procurement and contract language to protect against, and mitigate if, it occurs.

Planned

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BASIS OF DESIGN REPORT

Risk # Risk Description Undesirable Consequence RCM Ranking Update

39 Minor equipment not operating as intended or specified

Unit process failure leading to replacement costs, operations costs and permit violations

General contract language to protect against.

Planned

40 Incorrectly sized equip-ment both process and nonprocess (e.g., HVAC) equipment

Unable to process required amounts or maintain adequate operating area conditions (temperature in FBI room)

Predesign and design definition that identifies all capacity assumptions.

Pilot tested key processes. Will use results

41 Compatibility of prepur-chased equipment with general contractor procured equipment

Delays, long-term O&M issues if not addressed, cost

General contract language and timely procured equipment information to incorporate into general contract, coupled with design definition.

Planned

42 Few contractors bid Higher construction cost Prequalify and advertise to generate interest.

Planned

43 Only single vendor bids on major equipment

Higher capital cost Maintain adequate flexibility in predesign to have a level playing field.

Planned

44 Timely authorization of contract awards

Construction delay/stoppage, air permit, results in landfill costs for cake disposal

Give adequate notice of pending awards, obtain stakeholder buy-in of pending awards.

Planned

47 Multiple contracts working in close proximity

Claims and delays to the overall project

Package and sequence procure and construct contracts to minimize inter-ference, delays and overlapping work.

Planned

50 Incinerator fails emissions testing

Project commissioning delayed and land filling and O&M costs escalate

Equipment procurement language that assures compliance and guaranties or bonds for costs associated with failure.

Planned

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Attachment A Detailed Schedule and Risk Register

Activity ID Activity Name Start Finish Rem Dur Budget Total Float

GBMSD R2GBMSD R2E2 07-Jun-12 A 30-Oct-18 1471 $565,545,205 44AS050 GBMSD Admin & Legal 07-Jun-12 A 30-Oct-18 1437 $3,750,000 44KEY PROJECKEY PROJECT MILESTONES 07-Jun-12 A 30-Oct-18 1395 $0 44A1000 Notice to Proceed 07-Jun-12 A 0 $0A9730 Completion of BODR after VE 24-Jun-13 0 $0 1439A9770 Completion of 30% Design Review 29-Aug-13 0 $0 1391A9760 Completion of 60% Design Review 14-Jan-14 0 $0 1293A9780 Completion of 90% Design Review 28-Apr-14 0 $0 1219A8340 Project Completion 30-Oct-18 0 $0 44

Project PhasProject Phase Summary 07-Jun-12 A 29-Aug-18 1428 $0 87A1010 Pre-Design 07-Jun-12 A 23-May-13 54 $0 1231A10180 Detail Design - Contract I 06-May-13 29-Oct-14 388 $0 48A10200 Detail Design - Contract II 06-May-13 20-Aug-14 338 $0 923A10210 Construction - Contract I 30-Oct-14 30-Oct-17 783 $0 47A10220 Demolition - Contract II 31-Oct-17 29-Aug-18 217 $0 87

Co-DigestionCo-Digestion Bench Scale Testing 07-Jun-12 A 11-Mar-13 1 $0 1514A8380 Develop Testing Protocol 07-Jun-12 A 19-Jun-12 A 0 $0AA040 Additional Task 4 - Digester Bench Testing 07-Jun-12 A 11-Mar-13 1 $0 1480A8390 GBMSD Reviews & Approves Testing Protocol 20-Jun-12 A 20-Jun-12 A 0 $0A8400 Set-up Subcontract with University 22-Jun-12 A 29-Jun-12 A 0 $0A8410 Phase I Digestion Test of Plant Sludge & Industrial Waste - Set-up 02-Jul-12 A 11-Jul-12 A 0 $0A8420 Phase I Digestion Test of Plant Sludge & Industrial Waste - Test & Collect Data (Raw Sludge Sample... 07-Jul-12 A 21-Oct-12 A 0 $0A9720 ***RECEIVE INEFFECTIVE SEED SLUDGE SAMPLE AND RECOLLECT SEED SLUDGE FROM AL... 30-Jul-12 A 07-Sep-12 A 0 $0A8430 Phase I Digestion Test of Plant Sludge & Industrial Waste - Prepare Report to be included in Co-Dige... 22-Oct-12 A 08-Feb-13 A 0 $0A8430T07 ***FRAGNET 7 - CONTINUOUS LATE DATA ARRIVING FROM MARQUETTE*** 22-Oct-12 A 30-Nov-12 A 0 $0A10830 Phase I Digestion Test of Plant Sludge & Industrial Waste - Test & Collect Data (Raw Sludge Sample... 29-Oct-12 A 01-Feb-13 A 0 $0A8460T06 ***FRAGNET 6 - AWAITING FINALIZATION OF PROTOCOL/NEGOTIATE NEW SCOPE*** 30-Oct-12 A 30-Nov-12 A 0 $0A8460 Phase II Co-Digestion Test of Industrial Waste - Test & Collect Data (Treated Digested Sample) 01-Dec-12 A 03-Feb-13 A 0 $0A8470 Phase II Co-Digestion Test of Industrial Waste - Revised Phase 1 Report with Phase 2 Results 04-Feb-13 A 13-Feb-13 A 0 $0A8480 GBMSD Review as Part of Co-Digestion TM 13-Feb-13 A 13-Feb-13 A 0 $0A8490 Finalize Digestion/Co-Digestion Test TM 14-Feb-13 A 11-Mar-13 1 $0 1507

Task 1 - GBMTask 1 - GBMSD Design Requirements 02-Jul-12 A 03-Feb-14 236 $324,524 1279A1020 Mobilization 02-Jul-12 A 08-Aug-12 A 0 $0A0010 Task 1 - GBMSD Design Requirements 02-Jul-12 A 03-Feb-14 229 $324,524 1252Task 1.A - PrTask 1.A - Prepare Basis of Design Report Outline 05-Jul-12 A 20-Mar-13 8 $0 1507A1040 Prepare Draft (Section 1) 05-Jul-12 A 02-Nov-12 A 0 $0A1050 GBMSD Review 05-Nov-12 A 02-Feb-13 A 0 $0A1060 Incorporate GBMSD Review Comments 11-Mar-13 20-Mar-13 8 $0 1507

Group A RepGroup A Reports 20-Aug-12 A 02-Aug-13 105 $0 1410Task 1.B - PTask 1.B - Prepare Process Design Manual 20-Aug-12 A 03-Apr-13 18 $0 1497A1090 Prepare Draft 20-Aug-12 A 16-Nov-12 A 0 $0A8720 GBMSD Preliminary Review 01-Jan-13 A 22-Mar-13 10 $0 1497A8730 Incorporate GBMSD Review Comments 25-Mar-13 28-Mar-13 4 $0 1490A8740 GBMSD Validation 29-Mar-13 03-Apr-13 4 $0 1497

Task 1.C - PTask 1.C - Prepare Project Manual 25-Jan-13 A 30-Apr-13 37 $0 51A1110 Prepare Draft 25-Jan-13 A 01-Apr-13 16 $0 49A8840 GBMSE Preliminary Review 02-Apr-13 12-Apr-13 9 $0 49A9800 GBMSD Workshop 16-Apr-13 16-Apr-13 0 $0 30A8850 Incorporate GBMSD Review Comments 17-Apr-13 24-Apr-13 6 $0 49A8860 GBMSD Validation 25-Apr-13 30-Apr-13 4 $0 51

Task 1.D - PTask 1.D - Prepare Construction Manual 01-Apr-13 02-Aug-13 90 $0 1410A1130 Prepare Draft 01-Apr-13 31-May-13 45 $0 1413A8870 GBMSE Preliminary Review 03-Jun-13 13-Jun-13 9 $0 1413

J A J A J A J A J A J J A J A A A A A A2012 2013 2014 2015 2016 2017 2018

Notice to ProceedCompletion of BODR after VE

Completion of 30% Design ReviewCompletion of 60% Design Review

Completion of 90% Design Review

Pre-DesignDetail Design - Contract I

Detail Design - Contract IIConstruction - Co

De

Develop Testing ProtocolAdditional Task 4 - Digester Bench Testing

GBMSD Reviews & Approves Testing ProtocolSet-up Subcontract with UniversityPhase I Digestion Test of Plant Sludge & Industrial Waste - Set-up

Phase I Digestion Test of Plant Sludge & Industrial Waste - Test & Collect Data (Raw Sludge Sample) Part 1***RECEIVE INEFFECTIVE SEED SLUDGE SAMPLE AND RECOLLECT SEED SLUDGE FROM ALTERNAT

Phase I Digestion Test of Plant Sludge & Industrial Waste - Prepare Report to be included in Co-Diges***FRAGNET 7 - CONTINUOUS LATE DATA ARRIVING FROM