Water Design-Build Council Blog

How an Integrated Process System Optimized Delivery Speed and Value for a New Wastewater Treatment Plant

Posted by Steve Green, Northwest Municipal Market Manager Xylem Inc. on Fri, Aug 04, 2017 @ 05:10 PM

image4 (1).jpgIn 2014, the town of Berthoud, located on the Front Range of Colorado, north of Denver along the I-25 corridor, was faced with development requests from a combination of residential, commercial, and light industrial users. This request coincided with the implementation of stringent nutrient regulations by the State of Colorado for new wastewater treatment facilities. With the planned development of the eastern area of the community, particularly a major complex serving the trucking industry, a new east-side treatment facility would be necessary to sustain the planned growth of the city to the east of the existing service area. As a result, Berthoud officials made the decision to build a new wastewater treatment plant under an expedited schedule to accommodate the growth on the eastern part of the town.

The project proceeded initially as a traditional Design-Bid-Build approach until it became clear that approach would not be able to meet the project budget or timing needs. At that time, Berthoud officials decided to utilize the Construction Management at-Risk (CMAR) project delivery method and a competitive CMAR request for proposals was sent to pre-qualified contractors along with 50 percent design documents. Fisher Construction Inc. was selected as the CMAR with JVA continuing on as the design consultant. The collaborative delivery team invited Xylem Inc. to supply an integrated package of major process equipment for the plant, inclusive of influent pumps, Sequencing Batch Reactor, UV disinfection system, effluent pumps, and digester aeration equipment. Since Colorado has tight effluent limits on new plants being built since 2012, town officials and the design-engineer pre-selected the treatment process incorporating Xylem’s specialized equipment, all of which was delivered as an integrated system. The combined approach of the CMAR delivery model and the major equipment integration brought the project to a timely completion within the project budget.

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The Wedeco TAKSmart prefabricated stainless steel UV disinfection channels speed installation and minimize total construction costs.

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The Sanitaire ICEAS® advanced SBR system in the foreground, uses a VFD actuator to achieve constant decant rates from the basin.

Xylem’s advanced Sequencing Batch Reactor (SBR) – the Sanitaire ICEAS (Intermittent Cycle Extended Aeration System) - allows for continuous inflow to the biological treatment basins and utilizes the advanced NDNP (Nitrification, Denitrification, Bio-Phosphorus Reduction) process cycle which can consistently meet the effluent limit of Total Phosphorus at 0.7 mg/l. The Wedeco (a Xylem brand) TAKSmart open channel UV system was delivered to the construction site in a pre-fabricated stainless steel channel to minimize construction efforts, and the pumping process and disinfection equipment controls were integrated into a single system, optimizing the overall cost and timing associated with procurement and installation. This project delivery approach resulted in total project cost reduction of nearly $1 million below the original Guaranteed Maximum Price, ultimately enabling the town to meet the $4.45 million project budget.

Steve Green is the Municipal Market Manager for Xylem Inc., based in Portland, Oregon.  Steve’s focus is to grow and maintain Xylem’s reputation as the best-in-class provider of water and wastewater equipment and services to municipal clients in North America. 

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Topics: Wastewater Treatment