title
APPROVE AGREEMENT WITH ALFA LAVAL, INC. TO REBUILD A BELT FILTER PRESS AT THE REGIONAL WASTEWATER CONTROL FACILITY
recommended action
RECOMMENDATION
It is recommended that the City Council approve by motion findings for an exception to the competitive bid process and authorize an agreement in the amount of $252,000 with Alfa Laval, Inc. of Houston, Texas to rebuild a belt filter press at the Regional Wastewater Control Facility.
It is further recommended that the City Manager be authorized to take appropriate action to carry out the purpose and intent of this motion.
body
Summary
The Regional Wastewater Control Facility (RWCF) is required to treat wastewater collected from the City and discharge it into the San Joaquin River. This process includes the collection and treatment of sludge settled from the wastewater. Once treated, the sludge still maintains a high water content, which needs to be reduced prior to loading, transport and land application. The RWCF operates two machines called belt filter presses that remove excess water from the sludge to produce bio-solids. The lower water content in the bio-solids equals lower transportation and land application costs.
Last year, one of the two belt filter presses was successfully rebuilt by Alfa Laval, Inc. formerly Ashbrook Simon-Hartley. The Alfa Laval program for older models reconditions and upgrades the equipment as a cost-efficient alternative to purchasing a new model that may cost up to half a million dollars. The rebuilt press is now in operation, and the second 35-year old press is frequently out of service and needs to be rebuilt or replaced.
If approved, this action will authorize an agreement with Alfa Laval Inc. of Houston, Texas to rebuild the second belt filter press at the RWCF. The recommended action will allow the purchase of the parts and services under this same program to rebuild the belt filter press (Attachment A).
DISCUSSION
Background
Solid materials suspended in wastewater undergo many treatment processes at the RWCF including flocculation, settling, digestion, dewatering, transport and finally land-application. Dewatering of sludge at the RWCF is done with two machines that physically press water from sludge. When effective, these belt filter presses can remove water and increase the solids content from 2.5 percent coming into the presses to over 20 percent after pressing. Loading, transportation, and land application costs are based on wet ton measurements making it more cost effective for the City to remove as much water as possible from the bio-solids prior to hauling off-site by a contract vendor.
Present Situation
In June 2014, the City Council approved the rebuild of the first belt filter press under a contract with Alfa Laval, Inc. The rebuild and start-up of this press was successfully completed in December 2014, and the equipment is currently on-line and operating. With only one press operating reliably, it is difficult to dewater the volume of sludge produced during the treatment of average daily sewage inflows of approximately 30 million gallons a day. This often necessitates the need for contractor dewatering support to keep up, but this is cost prohibitive.
Alfa Laval, Inc. continues to offer a rebuild program on early model Ashbrook belt filter presses as an alternative to purchasing new equipment. The rebuild consists of on-site machine reconditioning and component upgrades that will meet the latest design and production standards, and includes a 1-year warranty of the rebuilt press. This program offered by Alfa Laval, Inc. is unique in that other companies do not offer similar rebuild programs to upgrade older presses with newer technology. The cost for the rebuild is approximately half that of the $475,000 for a new press. The purchase of a new press was considered, but the cost of the new press was not justified when compared to the working functionality of a rebuilt press. The extent of the rebuild essentially replaces vital parts and electronics resulting in a new press that will meet production needs for years to come.
In addition, the City will realize extra cost savings and increased equipment utility with the rebuild of the second press. This includes 1) the footprint of the rebuilt press will not change and will remain the same as the existing, eliminating the need to spend money on building redesign, remodeling and construction costs; 2) Replacement parts for both presses will be interchangeable and kept in stock at the RWCF, thereby reducing the cost of in-stock parts; and 3) the maintenance requirement of both presses will be the same optimizing workforce training, preventive maintenance schedules and effort.
This type of machinery is quite specialized and unfortunately a new press or the rebuild program is not available locally or within the County. A search of potential companies within California that could supply either the same rebuild program service or a new press produced a listing of several companies that only serve as sales representatives to Alfa Laval, Inc., which would only increase overhead costs without improving the desired service.
Findings
Stockton Municipal Code Section 3.68.070 provides for an exception to the competitive bidding requirements for purchases in excess of $75,000 in cases where the City Council has approved findings that support and justify exceptions to the competitive bidding process.
Proposed findings to support this purchase are as follows:
• The second Ashbrook belt filter press rebuild is needed as soon as possible to improve sludge processing, eliminate contract pressing, and reduce disposal costs. A full bid process to find a comparable new press will delay installation, increase costs, and affect the RWCF’s ability to effectively process waste.
• Alfa Laval, Inc., formerly Ashbrook Simon-Hartley, offers a rebuild program for its older belt presses, which are currently in use at the RWCF. All supporting infrastructure, connections and tooling are designed for the earlier model Ashbrook press.
• A search of other companies found that they do not offer similar rebuild services with the required technology upgrades, and warranty for the press currently in use at the RWCF.
• Changing to another brand would delay installation and require redesign of associated infrastructure at a greater cost to the City.
• Repair tools and replacement parts are consistent between both presses. Purchasing a different brand of press following a bid will increase the cost of tooling and supplies for repair and maintenance.
Therefore, staff recommends the City Council approve these findings as an exception to the competitive bid process and enter into an agreement in the amount of $252,000 with Alfa Laval, Inc. of Houston, Texas to rebuild the second belt filter press at the Regional Wastewater Control Facility.
FINANCIAL SUMMARY
The cost for the belt press rebuild is $252,000. Sufficient funds are available in account 431-4331-575 (Wastewater Treatment Plant Maintenance) for this proposed purchase.
There is no impact to the General Fund, or any other unrestricted fund, from this action.
Attachment A - Contract with Alfa Laval