LOWER MOLONGLO WATER QUALITY CONTROL CENTRE (LMWQCC) SOLIDS HANDLING SYSTEM UPGRADE PRELIMINARY DESIGN

Expressions of Interest Pre-Qualification Requirements Brief Tender No. 1083/12

April 2012

ActewAGL Distribution
ABN 76 670 568 688 GPO Box 366 CANBERRA ACT 2601

LMWQCC SOLIDS HANDLING SYSTEM UPGRADE PRELIMINARY DESIGN

Pre-Qualification Requirements Brief

Introduction

On Saturday 21 April 2012, ActewAGL, on behalf of ACTEW Corporation Ltd, ABN 86 069 381 960, (ACTEW) invited Expressions of Interest (EOI) for the preliminary design of aspects of the Solids Handling System Upgrade at the Lower Molonglo Water Quality Control Centre [LMWQCC]. This Expression of Interest (EOI) Pre-qualification Requirements Brief sets out: an overview of the Project; information regarding the Project to enable prospective Proponents to assess whether or not they have the capabilities sought by ActewAGL; and the matters to be addressed by prospective Proponents to establish their capability (ie content and format of the Pre-qualification submission) .

Only Proponents who have: applied for pre-qualification; and subsequently been pre-qualified (i.e., assessed by ActewAGL in their absolute discretion as having the capability),

will be invited to submit proposals for the Preliminary Design. The invitation is referred to in the remainder of this Pre-qualification Requirements Brief as the Request for Proposal for the concept and preliminary design (RFP). ActewAGL is not required to give reasons for its assessment of the capability of any prospective Proponent. Although ActewAGL intends at this time to proceed with the Request for Proposal process described in this Pre-qualification Requirements Brief, it nevertheless reserves the right to amend the process to procure the preliminary design. ActewAGL will not (and will not be liable to) reimburse any respondent to the invitation contained in this Pre-qualification Requirements Brief or any proponent responding to the RFP for any costs directly or indirectly incurred in relation to the pre-qualification process or the RFP.

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2.1

Overview of Project
Lower Molonglo Water Quality Control Centre (LMWQCC)

Current treatment facilities

The existing wastewater treatment plant is located approximately 16 kilometres from the centre of Canberra in the suburb of Holt (ACT). The plant is situated near the confluence of the Molonglo and Murrumbidgee Rivers. LMWQCC is the main wastewater treatment plant for the ACT. The plant treats wastewater using a combination of physical, chemical and biological treatments with the solids (including sewage sludge, grit, rags and screenings) removed from the treatment process and incinerated in two multiple hearth furnace, the sludge is dewatered in centrifuges and the cake fed into the furnaces. The furnaces have been in operation since 1978 and ActewAGL is looking to improve furnace and ancillerys performance and improve air emissions. Operation of the furnaces, including emissions, is regulated under Schedule 2 of the Environmental Authorisation.

2.2

Project Overview

Initial upgrade investigations have determined that the existing incineration can continue in use up to (and possibly beyond) 2028, however to meet the existing and future air emission licence conditions, upgrades to the feed, furnace and emission systems are required. The selected design consultant(s) will complete the Preliminary Design under RFT 1083/12 for the following: 1. CFD Modelling of the Incineration process; 2. Screenings and Grit systems; 3. Sludge and Feed systems; 4. Furnace and Exhaust systems; 5. Foul Air system. Background information for each of the above work packs is found below in Sections 2.3 to 2.7. The purpose of the preliminary design is to provide clear recommendations with substantiated supporting reasons, general arrangement drawings and budgets which allow ActewAGL to proceed with detailed design and construction confident that ACTEWs requirement for the upgrade will be met and that the full scope of the upgrade is well justified. The scope includes condition and capacity assessment of the existing solids handling system of LMWQCC. RFT 1083/12 allows ActewAGL to engage separate consultants for each of the above work packs. However there may be advantages to engaging a consultant for the preliminary design of some or all work packs. Consultants will have the opportunity to offer ActewAGL a discount should they be awarded more than one work pack.

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2.3

Proposed CFD Modelling of the Incineration Process

Computational Fluid Dynamic (CFD) modelling of the existing incineration process is required to determine a basis for proposed upgrades to the feed systems, the furnaces and auxiliary equipment and the emission control systems. Recommendations regarding positioning and specification of instrumentation on the furnace and auxiliary equipment is required to enable accurate data capture over a 6 9 month period for the CFD modelling. Once the existing operation has been modelled, numerous simulations will be undertaken to determine the optimal arrangement and set-up of the incineration process. From this optimal recommendation the detailed design of the solids handling system will be undertaken. Some of the modelling outputs required are: Temperature patterns through the process; Solid flows through the process; Gaseous and air flows through the process; Optimisation of combustion patterns (burners, solid wastes, etc.); Optimisation of air/fuel usage and ratios; Predicted emissions through the stack and disbursement patterns; Optimised balance between fuel and the three waste streams (screenings, grit and sludge).

There will be a requirement that the CFD model can be modified to enable accurate on-line simulations that will be used to control the daily operation of the incineration process by the operators and furnace control systems. The preliminary design will include: Recommendations relating to location and specification of instrumentation required on the furnace and auxiliary equipment to enable accurate data collection; Collection of data over a 9 month period; Modelling of the current incineration process (CFD modelling) Carrying out multiple simulations to ascertain the optimal arrangement, flows, combustion patterns and operation of the incineration process; Simplification of the CFD model to allow it to be implemented into the SCADA system and used as a real time model so as to automate the incineration operation;

2.4

Screening and Grit System Investigations

Screenings are the large detritus which is removed from wastewater by fine screens. It comprises items such as rags, plastics, nappies, paper, vegetable matter, etc. There is no commercial or intrinsic value of screenings and they constitute a potential health hazard. The screenings are removed on 3mm fine screens, macerated, dewatered and then pumped to the sludge holding tank, which provides some balancing storage before the centrifuges.

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Pre-Qualification Requirements Brief The grit collected at LMWQCC consists of fine sand and soil particles and heavy solids generally between 0.3 and 2mm in size which settles in specially designed tanks. Grit is dewatered on screw classifiers and fed into the top of the furnaces. Virtually all treatment plants, except for LMWQCC generally dispose of screenings and grit at landfill sites. The preliminary design should include a full investigation into the existing grit and screening system capabilities to ascertain what improvements are required to supply the furnaces with a consistent and reliable fuel source throughout the day. The preliminary design should also consider the addition of a 4th fine screen to cope with additional flows due to population growth. The screenings blending tank is undersized and therefore blending is occurring in the sludge holding tank. The preliminary design should review capacities throughout screening and grit systems to provide appropriate handling and sufficient storage for optimal incineration operation. Hydraulic modelling of the systems will be required to simulate current and future loadings through the screenings and grit systems In addition to the above, there are specific issues with the screenings and grit systems that have been highlighted by ActewAGL Treatment Branch (Operations) through a scoping workshop, these will be detailed in the work pack scope, but include: Lack of metal detection on the screening system, options for metal removal are required; Poor screening wet well operation, can not remove all solids and it can not be isolated from the macerator pumps, investigate options; Constant blocking of the screening pumps (discharge side); Grit is getting past the 3mm fine screens and settling out in the blending tank; Inability to sustain grit flowing and recirculating whilst the furnace is off-line in order to prevent the grit tanks from blocking up.

2.5

Sludge and Feed System Investigations

One of the major contributors to the poor incineration performance is the inconsistency and variability in composition of the cake fed into the furnace. A detailed investigation into the sludge and feed systems is required to identify improvements required to deliver a consistent mix and feed 24 hours a day. These investigation will include: Sludge Dewatering polymer system; Sludge holding tank and room; Sludge pumping system; Centrifuges; Feed systems.

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Pre-Qualification Requirements Brief Hydraulic modelling will be required to identify limitations in the process and provide justification of the recommendations made by the consultants. The existing sludge holding tank presents some process issues, there is also no redundancy in the sludge holding tank. The mixing in the tank is not even and needs to be addressed, as do maintenance access issues. The mixing of screenings and sludge in the sludge holding tank causes feed issues through the centrifuges. The preliminary design needs to investigate options for seperating the process routes for the screenings, grit and the sludge. There are specific concerns that must also be addressed which the operators have highlighted, these will be detailed in the scope for this work pack, but include: H2S monitoring in the sludge room; Emergency truck loading facility needs to be improved; Additional storage requirements. The options and reccomendations for how to feed the cake, screenings and grit into the furnaces also need to be included in the preliminary design, for example are the existing screw conveyors the best option or would a pumped system be better suited to delivering a consistent feed? The consultant shall provide GA drawings for any recommendations made, along with cost estimations for all proposals.

2.6

Furnace and Exhaust System Investigations

The current incineration system at LMWQCC includes a duty/standby (Maintenance) arrangement consisting of a multi hearth furnace (9 hearths), cyclones, afterburners (decommissioned), a wet scrubber and ash handling system, as well as shaft cooling, exhaust ducting and equipment, stack monitoring and the stack itself. The original design point of the furnaces was for a feed based on 12-18% solid content, which is much wetter than the current feed average of 34% solids. As a result instead of the cake drying in the first 3 hearths of the furnace, then burning in the next 3 hearths, followed by cooling in the final 3 hearths the cake is burning in the first 2 hearths hence causing the issues with emission compliance. The exceedences of the current licence conditions are predominantly down to excess Carbon Monoxide, Opacity and NOx. All three conditions need to be addressed in the exhaust system, recommendations and reasonings are required along with layouts and budgets for the required works. The preliminary design of the furnace and exhaust system will depend upon the results of the CFD model being undertaken, therefore this work pack will not commence until the CFD model has simulated the optimal configuration determined. However to asist in assertaining

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Pre-Qualification Requirements Brief experience and qualifications to under take the preliminary design work, the consultant should consider the concept design, which included: Install ammonia injection system (or alternative system) for control of NOx; Install wet electrostatic precipitator (or alternative system) for removal of particulates; Install regenerative thermal oxidiser (or alternative system) for reduction of carbon monoxide; Move the furnace feed points from Hearth #1 to Hearth #3 (with separate feeds for screenings, cake and grit) to move combustion lower; Automate excess air flow control to provide greater operating control; The preliminary design will make recommendations relating to the optimal configuration based on the CFD modelling, including proposed floor plans identifying if there is sufficient room in the current layout or if additional buildings will be required. The preliminary design should make recommendations for energy recovery (heat to power), along with costs associated with all the proposed works. The current system returns waste heat from the wet scrubbers back into the biological process (increasing the main biological temperatures by 3C in winter), this energy recovery must be maintained in any new proposal.

In addition to the work described above, several specific issues with this system need to be investigated during the preliminary design, as highlighted by the operations team in the scoping workshop, this will be detailed in the work pack scope, however it includes: No ability to control flare-ups on the furnace; Off gas unit installed on Furnace 1 but it never worked and has been disconnected, investigate why it never worked and make recommendations to its re-instatement or removal; Ageing ash cooling system (30 years old); Issues with ID fan and valve, no redundancy, ageing equipment, unreliable and no monitoring; Stack height/size causing OH&S issues with the stack emissions blowing back inside the incineration building.

2.7

Foul Air System Investigations

There are several issues surrounding the existing foul air systems. The H2S monitoring is not sufficient and on flare up of the furnaces there is the potential of fires caused by build up of gasses and also combustible solids in the ducting and the feed system. The preliminary design needs to conduct a thorough investigation into the existing system, followed by detailed recommendations and pricing to allow the foul air system to comply with relevant OH&S legislation. Since the foul air system is dependent on the outcomes of the CFD modelling, this work pack will commence after the CFD modelling has been concluded. The sizing and location of the foul air stack also needs to be considered in this preliminary design.
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2.8

Project Delivery Timetable

Requests for Proposal (RFP) process

Following receipt of Expressions of Interest, it is proposed to complete the RFP process according to the timeline as set out below: Ref. 1. 2. Activity This Pre-qualification Requirements Brief will be issued by email to registered parties. Pre-qualification submissions must be received by: Date Saturday 21 April 2012 Tuesday 22 May 2012 2 pm Australian Eastern Standard Time Friday 29 June 2012

3. 4.

ActewAGL/ACTEW review of submissions. ActewAGL plans to notify pre-qualified Proponents on or before:

Due to the dependency on the CFD modelling outcomes on several of the work packs, the preliminary design work for each work pack will commence independently, the table below gives indicative dates for the commencement of the RFT process for each work pack (the award of the contract and start of the preliminary design will subsequently follow), however ActewAGL reserve the right to alter any of the commencement dates and will provide the sucessfull consultant with a minimum of four weeks notice prior to the target date. Ref. 5. Activity Target date for issue of the RFT documents for the preliminary design consultancy for the CFD Modelling of the Incineration process (work pack 1). Target date for issue of the RFT documents for the preliminary design consultancy for the Screenings and Grit Systems (work pack 2). Target date for issue of the RFT documents for the preliminary design consultancy for the Sludge and Feed Systems (work pack 3). Target date for issue of the RFT documents for the preliminary design consultancy for the Furnace and Exhaust Systems (work pack 4). Target date for issue of the RFT documents for the preliminary design consultancy for the Foul Air System (work pack 5). Indicative Date Monday 6 August 2012 Monday 3 September 2012 Monday 8 April 2013

6.

7.

8.

Monday 1 July 2013

9.

Monday 2 September 2013

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Pre-Qualification Requirements Brief ActewAGL project staff and stakeholders will actively review draft submissions from the consultant(s) throughout the development of the preliminary design.

Pre-qualification Selection Criteria

2.9

Summary of Pre-qualification Criteria

ActewAGL is seeking Consultants that are able to provide an integrated project design delivery capability for the preliminary design of the upgrades to the solids handling systems at LMWQCC. The following pre-qualification criteria will be used: Experience in producing Computational Fluid Dynamic models of solid waste incineration processes, preferably within multi hearth furnaces (this is for work pack one only) Experience in the design of major Wastewater Treatment Plants including Solids Handling Systems; Skills and experience of Key Personnel the skills and experience of the nominated Key Personnel in delivering the preliminary design and/or detailed design of equivalent facilities. The experience of the consultants nominated project manager, senior wastewater treatment process designer, specialist process designer for each work pack, senior electrical engineer, senior mechanical engineer, senior hydraulic structures engineer and senior plant hydraulics engineer in delivering and designing equivalent facilities will be considered as critical capabilities in the assessment; and Adequacy and Commitment of Resources the Consultant must be able to demonstrate that their team has the required resources to undertake the Project, in terms of both number and quality of staff, and must commit to the nominated Key Personnel being made available for the Project within the required Project timelines.

Referees may also be checked and taken into account in assessing skills, experience and capability.

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3.1

Submission Requirements
Format of Submissions

Pre-qualification submissions are to be a maximum of 17 pages in length (single spaced A4, 11 point text), in addition to an executive summary or cover letter of not more than 2 A4 pages. The required format is as follows: 1. Corporate Information 2. Principal qualifying characteristics statement 3. Reference projects 4. Committed Key Personnel (max. 1 page per person)

maximum 1 page maximum 2 pages maximum 2 pages maximum 12 pages

3.2 Submission Contents Corporate Information

Length: Content: maximum 1 page Corporate details Postal Address Street Address (for courier delivery) Contact details for the representative of the Consultant for the purposes of receiving all correspondence regarding this pre-qualification and RFP process, Prequalification submissions, including mobile telephone and email.

Principal qualifying characteristics statement

Length: Content: maximum 2 pages Summary of: Technical competence Experience in the detailed design of major wastewater/solid handling system projects Project delivery management competence

Reference projects
Length: Content: maximum 2 pages The specific experience and expertise of the proponent in the development and completion of major waste water treatment projects, particularly of the nature envisaged in this EOI document: Project titles and description (including the capital value of projects), include dates when project was undertaken; Client names and referee names (including current phone numbers); Scope of consultants involvement on the project; The type of project delivery contract utilised on the project; Identify which Key Personnel have carried out primary roles on these projects.

Key personnel
Length: Content: maximum 12 pages Precise summary CVs of key personnel that the prospective Proponent will commit to the project if successful (max. 1 page per person) Indicative list of Key Personnel:
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Pre-Qualification Requirements Brief Consultants Project Manager Wastewater treatment senior process engineer Specialist process designer for each work pack (5 No.) Senior plant hydraulics engineer Senior hydraulic structures engineer Senior mechanical engineer Senior electrical & controls engineer CFD Modelling experts (where required)

3.3

Lodgement of RFP Documents

RFPs submitted to the Tender Box shall be returned enclosed in a sealed envelope endorsed with the tender number (1083/12) and closing date (22 May 2012) to: The Tender Box Procurement and Supply Branch ActewAGL Distribution 40 Bunda Street CANBERRA CITY ACT 2601 Please note, this is not a postal address, deliveries must be made either by courier or in person during normal working hours. RFPs can also be: Emailed to address tenderbox@ActewAGL.com.au provided that the signed original RFP documents are received within seventy-two (72) hours of closing time. Failure to comply may render the Tender invalid.

3.4

RFP Closing Time Verbal Offers Late Submissions

Tenders close at 2 pm (Australian Eastern Standard Time) on Tuesday 22nd May 2012.

3.5

ActewAGL will not accept verbal offers.

3.6

ActewAGL will only accept late tenders in exceptional circumstances. Acceptance will be conditional upon establishing conclusively that the integrity of the process has not been compromised, and that late acceptance does not result in any administrative delay. The acceptance of late tenders will be at the sole discretion of ActewAGL.

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4.1

Pre-Qualification
Assessment

ACTEW and ActewAGL plan to assess properly submitted Pre-qualification Applications, using the criteria identified in Section 2.9, on or before Friday 29 June 2012.

4.2

Requests for Additional Information

It is not anticipated that additional information will be requested from any prospective Proponent. Nevertheless ACTEW and ActewAGL reserve the right to do so in order to clarify any aspect of any particular Pre-qualification Application. Any request for additional information will be forwarded in writing to the address and contact person nominated by the prospective Proponent in their Pre-qualification application.

4.3

Notification

ACTEW and ActewAGL will advise all prospective Proponents, on or before Friday 29 June 2012, whether or not they have been pre-qualified for the remainder of the RFP process. Neither ACTEW nor ActewAGL is obliged to entertain or participate in any discussion or correspondence with any prospective Proponent about their Pre-qualification application, its treatment, acceptance or rejection by them or any representation seeking further consideration by ACTEW and ActewAGL about their decisions.

Further Information

If further information regarding the Project is required by any prospective Proponent, requests may be directed to ActewAGL via email CX10677@actewagl.com.au. ActewAGL / ACTEW Corporation will not be bound by any verbal advice given or any information furnished by any officer or agent in relation to the pre-qualification or RFP process, but will be bound only by written advice or information furnished by an authorised officer.

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Appendix A
Process Flow Schematic Diagram. Drg.# LM8P0-0059 (Rev 3) Furnace Exhaust Gas System Schematic Diagram. Drg.# LM1M0-0243 (Rev 1) Sludge and Incineration Plant Flow Diagram. Drg.# LM1M0-0001 (Rev D) Furnaces and Auxillary Equipment GA Drg.# LM1G0-0008 (Rev A) PSD Lower Molonglo Furnaces Report July 2009 ACVM Scoping Review Workshop Report Version 5 (February 2012) ActewAGL CX10677 Scoping Document Version 3 (March 2012)

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