===== PDF PAGE 89 ===== [Extraction: embedded PDF text] CITY OF WEST CHICAGO INFRASTRUCTURE COMMITTEE AGENDA ITEM SUMMARY ITEM TITLE: AGENDA ITEM NUMBER: _Lf_..__.'""""E_.___• _ _ Resolution No. 21-R-0016 - Contract Award - Layne Christensen Company for Professional Services Related to COMMITTEE AGENDA DATE: March 4, 2021 the 2021 Well Station No. 10 Rehabilitation Project COUNCIL AGENDA DATE: March 15, 2021 STAFF REVIEW: Rocky Horvath, Utility Superintendent SIGNATURE APPROVED BY CITY ADMINISTRATOR: Michael L. Guttman SIGNATURE. _________ _ ITEM SUMMARY: Well Station No. 10, located at 2290 Smith Road, is one of five City-owned deep wells with a Byron Jackson well pump and motor assembly extending to approximately 1,423 feet below ground and rated to pump 1,025 gallons per minute. The well was originally constructed in 1997 and was serviced in 2006 and 2011. Prior to that 2006 service event, the column pipe suffered a structural failure and the well assembly had to be retrieved from the bottom of the well. The service at that time included wear ring replacement in the pump bowl assembly and a refurbishment of the motor at the Byron Jackson repair facility. The well was returned to service in January of 2006. In February 2011, this well failed during a routine run event and would not restart. Technicians were called in to further investigate and subsequent testing revealed that a ground fault condition existed at the motor; the well assembly was pulled by Layne Christensen Company in May 2011 and shipped to the Byron Jackson repair facility for inspection. Analysis by Byron Jackson technicians revealed that the motor had failed completely and needed extensive rebuilding or replacement. Since the cost to repair the motor was significantly higher than the cost of a factory refurbished motor of identical specifications; Layne Christensen Company was authorized to replace the motor. The well assembly was restored to service in October 2011. In June 2019, staff noticed that the production/pumping rate from the Well was decreasing. As of January 2021 the well remains operational; however, it is only pumping 667 gallons per minute. This 35% reduction in rated flow indicates the well assembly is due for inspection and service. Due to its history servicing the well and original equipment installation, staff solicited a proposal from Layne Christensen Company to pull, inspect, and rehabilitate the well assembly. Layne's proposal includes a complete rebuild and rehabilitation of the existing well equipment, including a television survey of the well casing. This proposal also contains estimated provisions for new column pipe, cleaning and re-coating of the existing column pipe. The estimated total for these services is $181,992.00. One additional item addressed in this proposal is replacement of the well motor, if needed. The existing motor has a mercury seal system which needs to be inspected before reinstallation. If inspection determines the unit cannot be reused a new motor has been quoted at $115,772.00; for a total worst case scenario project cost of $297,764.00. At this time staff does not foresee a need to replace the motor. Following service, the well assembly will be re-installed, tested, and returned to service. City staff recommends the rehabilitation of the well assembly before the start of peak summer water system demand. To accomplish this, staff recommends that City Council authorize the Mayor to execute a contract with Layne Christensen Company, for an amount not to exceed $297,764.00, for services necessary to remove, inspect, repair, re-install, test and place the well assembly at Well Station No. 10 back into operation. ===== PDF PAGE 90 ===== [Extraction: embedded PDF text] CITY OF WEST CHICAGO There is $250,000 budgeted in the Water Fund (06-34-47-4420) for pump station repairs; which is adequate to rehabilitate Well Station No. 10, provided the motor does not be replaced. Should the motor need to be replaced, other non-critical scheduled projects will be moved to Fiscal Year 2022 to free up additional funds in Fiscal Year 2021. ACTIONS PROPOSED: Approve Resolution No. 21-R-0016 authorizing the Mayor to execute a contract with Layne Christensen Company, for an amount not to exceed $297,764.00, for professional services related to the 2021 Well Station No. 10 Rehabilitation Project. COMMITTEE RECOMMENDATION: ===== PDF PAGE 91 ===== [Extraction: embedded PDF text] RESOLUTION NO. 21-R-0016 A RESOLUTION AUTHORIZING THE MAYOR TO EXECUTE A CONTRACT AGREEMENT WITH LAYNE CHRISTENSEN COMPANY FOR PROFESSIONAL SERVICES RELATED TO THE 2021 WELL STATION NO. 10 REHABILITATION PROJECT BE IT RESOLVED by the City Council of the City of West Chicago, in regular session assembled, that the Mayor is hereby authorized to execute a Contract Agreement for Professional Services related to the 2021 Well Station No. 10 Rehabilitation Project, between the City of West Chicago and Layne Christensen Company, for an amount not to exceed $297,764.00, in substantially the form attached hereto and incorporated herein as Exhibit "A". APPROVED this 15th day of March, 2021. AYES: NAYES: ABSTAIN: ABSENT: Mayor ATTEST: City Clerk ===== PDF PAGE 92 ===== [Extraction: embedded PDF text] A GRAnlTE COMPANY February 17, 2021 City of West Chicago 475 Main Street West Chicago, IL 60185 Attn: Rocky Horvath, Water Superintendent Re: Well No. 10 - 300HP Byron Jackson Type H Submersible pump repair Rocky, Per your request, we are sending this letter to estimate the costs for the pulling, repairs, and reinstallation of the 300HP Byron Jackson submersible pump in Well No. 10. The pulling would be done to determine the reason for the 30% decrease in the well production, that you noticed last Spring. Layne has repaired the Well 10 pump twice in the past, since it was installed in 1997. In 2006, there was a complete pipe separation that involved significant repairs, including fishing a portion of the pump from the bottom of the well. In 2011, the motor failed, which required a major repair. The original all-bronze bowl was rebuilt also, plus eleven (11) pieces of pipe needed rethreading. Due to the nature of the situation, an exact cost cannot be determined until the pump has been pulled and inspected. However, for budgetary purposes, we have developed the list below, which includes all items that we believe will be required, as well as some items that may be needed on this 300HP, Type H 2300 volt Byron Jackson submersible deep sandstone well pump. • Mobilization to the site, pull the pump, briefly inspect on-site and measure the total depth and static water level. • Disassemble, inspect & possibly rebuilding of the Byron Jackson bronze bowl assembly. • Mobilize 1O" column pipe to our yard; sandblasting for inspection; and remobilize back to site. • Possible 1 O" T&C pipe repairs and re-epoxy coating, inside and out. • Service the Byron Jackson motor - change oil, epoxy coat exterior, check the seal float, etc. WATER RESOURCES 721 W. Illinois Avenue, Aurora, IL 60506 I Office: 630-897-6941 I Fax: 630-897-6976 I layne.com ===== PDF PAGE 93 ===== [Extraction: embedded PDF text] City of West Chicago Rocky Horvath, Water Superintendent Well No.10 February 17, 2021 Page 2 • New materials contingencies. • Reinstallation of the pump, including a test of the well and pump. Please note that the 300HP Byron Jackson Type H mercury motor seal should be balanced, and the motor dewatered in accordance with our exclusive procedure. This will allow the motor to be put in the proper shipping position with the mercury seal secured and will minimize the potential for water entering the motor windings, which would result in damage to the motor. Only Layne can provide a Byron Jackson factory authorized serviceman to complete this procedure properly. As a result of the new July 1, 2012 IEPA guidelines, we no longer conduct the seal servicing or motor dewatering over the well. To our knowledge Layne is the only contractor in the country that is currently utilizing a sealed motor service containment module that is transported to the project site to meet the new IEPA regulations. Our work will include COMPLETE adherence to these regulations. Pump repairs of this nature are normally performed on a time & material basis, per the rates, terms, & conditions as outlined on the attached Work Order Form. We would typically use a Large Pump Service rig, along with a Large Truck Crane, with combinations of 2-, 3-, & 4-man crews. Th e I'1s f mg o f th e 1'tems f or our T&M es f 1ma te .1s b re ken d own as f o II ows: • Mobilization, pulling, and brief inspection on the site with pump service crew $32,500.00 • Hydro crane and crew to load and haul bowl, cable, motor, etc. to yard $1,700.00 Disassemble, clean, & inspect all bronze bowl assembly $1,750.00 • • Sandblast 1O" pipe for inspection $3,500.00 Complete servicing of 300HP Type H Byron Jackson • motor, by Byron Jackson certified technician $5,500.00 • Hypot check of cable, lump sum $1,300.00 Television survey of well, lump sum $1,750.00 • 2 bl~ne A CiRAnrTE COMPANY ===== PDF PAGE 94 ===== [Extraction: embedded PDF text] City of West Chicago Rocky Horvath, Water Superintendent Well No. 10 February 17, 2021 Page 3 Rebuild 14 Stage -13MQ/12MQL Byron Jackson all • bronze fitted bowl assembly, if required. $14,500.00 • Miscellaneous materials, such as, sodium hypochlorite, HTH tablets, stainless steel banding and buckles, etc. $950.00 • Mobilization of bowl, cable, and motor to site and unload $1,700.00 • Pump service crew for reinstallation of pump, testing, and demobilization $30,500.00 Power tong usage, per 8-hour shift - est. 6 at $460.00 $2,760.00 • • Byron Jackson flat cable assembly $6,530.00 1O" T&C replacement pipe contingency, 250 ft. @ $18,000.00 • $72.00/ft. New No. 2, 2.4kV jacketed power cable, 875 ft. @ $0.00 • $24.00/ft =$21,000.00 - assume reusable 2 - 1O" surge control valves@ $1,689.00 ea . $3,378.00 • 15 - 1O" API Pipe couplings @ $258.00 ea . $3,870.00 • • Cutting & rethreading of an estimated 25 non-coupling pipe ends. $6,500.00 Mobilization of pipe, to & from our Aurora yard, est. 14 • hrs. @ $636.00 per hour $8,904.00 Sandblasting & epoxy coating of the 1O" pipe, inside & • out - 850' @ $34/ft. $28,900.00 • Miscellaneous Repairs ContinQencv $7,500.00 TOTAL ESTIMATED COST $181,992.00 We assume the pump can be pulled in a normal fashion without the need for any fishing for its removal from the well. A GRAmE COMPANY ===== PDF PAGE 95 ===== [Extraction: embedded PDF text] City of West Chicago Rocky Horvath, Water Superintendent Well No. 10 February 17, 2021 Page4 Since the motor is currently operating satisfactorily, the above pricing schedule is based upon the 300HP motor being reusable and completely serviceable, utilizing our unique, multi-step Byron Jackson Type H motor servicing procedure. If there are issues with the motor, requiring it be sent back to Flowserve/Byron Jackson for teardown & inspection, then a Byron Jackson 300HP factory exchange motor may be required. If so, the NET price to the City would be $115, 772.00, which includes the $11, 150.00 credit for the City's motor, plus estimated shipping costs of $2,200.00. The estimated time frame for the factory exchange motor would be at least 12 weeks, after the City's Motor is inspected. Once the pump has been removed, cleaned, & inspected, Layne would provide an updated repair cost estimate BEFORE proceeding with any repairs. Of course, if we encounter something needed that is out of the ordinary, we will include that in the updated estimate. This has been standard practice on the many repairs performed for the City in the past. We have not included a contingency for sand bailing, which in the past, does not look to have been needed. The time to execute this work, of course, depends upon what work is actually done. But if the motor is reusable and we are able to completely service it in our Aurora Service Center as part of this repair, we would estimate the following time frames: • Mobilize, pull & inspect. - 1+ weeks • Repairs - 4 to 6 weeks • Reinstallation and testing -1-1/2 weeks. Our current rig schedule would allow us to start this work in 1 to 1-1/2 weeks. Layne appreciates the opportunity to help the City with its water resource needs. If you have any questions, please do not hesitate to contact us. Yours Very Truly, Layne Christensen Company cJ"Aom.cu