Crystal Falls Township Water System Improvements Project

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Crystal Falls Township / Crystal Falls CityWater
System Improvement Projects
Crystal Falls Township Water System Improvements
Project

• Presented by Jeff Bal
• at the
• 59th Annual U.P. Water Institute Conference

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Crystal Falls Township Hall and Public Works
Garage
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Water Infrastructure Projects in the U.P.

• Crystal Falls Township - Typical Community
• Influenced by Mining Industry
• Aging Water System
• Did not meet Water System Reliability Standards
• Small Customer Base
• Needed to Reduce/Control Costs and Increase
  Customer Base to Generate and Preserve Revenue

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Crystal Falls Township Water System Improvements

• Need for Project
• Firm Capacity / System Reliability
• Leakage (60-70)
• Fire Flows (Minimal or Non-existent)
• Widespread Pressure Fluctuations
• - Little or no pressure at some homes during
  peak daily demand periods
• - Commercial Demands Could Not be Satisfied
• Large Need for System Updates and Mainline
  Replacement
• Wells
• Tanks
• Booster Pumps
• Etc.

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Large Widespread Service Areas

• Rehabilitation
• Need for Funding Assistance
• USDA-RD, EPA, MEDC, other

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City of Crystal Falls
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City of Crystal Falls Faced Similar Issues

• Influenced Mining Industry
• Aging Water System
• Aging Wells and Water Treatment System
• Shrinking Customer Base
• Needed to Reduce/Control Costs

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City of Crystal Falls

• Needed to either
• Develop New Water Supply Source or
• Construct New Treatment Plant due to High Iron
  and Manganese concentrations
• City also needs to upgrade distribution Piping
• All Costly Alternatives
• During 2004 - City was Unsuccessful in Finding
  new source for water of Suitable Quality
• City desired considering water agreement with
  Township

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Ultimately Cost Savings thru a Water Purchase
Agreement Would Provide Benefits to Both
Sidesbut it wouldnt be that easy
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City Township Water Agreement Negotiations
began March 25, 2005
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Crystal Falls Township Project Development

• 1998-2002 Preliminary Engineering
• 2002 Grant/Loan Application USDA-RD
• - 3,271,000 Grant (56)
• - 2,588,000 Loan 4.5 _at_ 40 Years
• 2002-05 RD Funding Delayed
• 2005 Township Received Special Appropriations
  Grant for 385,000
• 2005 RD Adjust Grant/Loan Offering to 2.27 Mil
  Grant / 3.59 Mil Loan
• 2005 RD Funding was Secured and Preliminary
  Design Work Began in Spring for 6 Million
  Township only Water Project
• Township Willing to discuss Water Agreement with
  City in Part due to Grant / Loan Revisions

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Crystal Falls Township Project Included

• Original Design Basis
• 250 GPM Firm Pumping Requirement for Lind System
• (1) Well Rehabilitation for Lind System
• (1) 50,000 Elevated tank to be removed
• (1) New Well For Townline Rd System for
  Reliability
• (1) New 200,000 Gallon Elevated Tank
• (2) Tanks Rehabilitated
• Approximately 70,000 Feet of New Water Main

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Township City Negotiations Intensify

• April 5, 2005
• April 28, 2005
• May 6, 2005
• July 19, 2005
• Draft Terms of Agreement Reached in August 2005
• Firm Capacity Requirements Established for Each
  Community
• Water Agreement Contingent upon Aquifer Testing
• Final Terms of Agreement Negotiated November 2005
  thru October 2006
• Agreement Signed October 3, 2006

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Crystal Falls Township Project Development

• Township/City Water Agreement (Deal of the
  Century)
• - City Agrees to Contribute 1.4 Million toward
  Township Project for Improvements Necessary to
  meet City Flow Requirements
• - All New Design Basis Developed 2006-07

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Crystal Falls Township Crystal Falls City

• Design Basis Includes
• 800 GPM Firm Pumping Requirement for Lind System
• (2) Wells Rehabilitation for Lind System
• (2) New Wells for Lind System
• (1) 50,000 Elevated tank to be removed
• (1) New Well For Townline Rd System for
  Reliability
• (1) New 500,000 Gallon Ground Storage Tank
• (2) Tanks Rehabilitated
• Approximately 72,000 Feet of New Water Main
• Master Control Meter Station to Control Flow to
  City
• Radio SCADA System
• Master Meter Station to Measure Flow Out of City

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City of Crystal Falls also Did Several Projects
at This Time

• Main Street Sewer Separation and Water Main
  Replacement 800,000
• City Transmission Main Upgrades 1,408,000
• Meter Installations for All Customers 500,000
• Projects Funded thru RD Loan and MEDC Grant

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Crystal Falls Township Water System

• 660 Customers
• 196,000 Feet of Pipe (37 Miles)
• 18 Customers per Mile of Piping
• 2 Completely Separated Systems

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Crystal Falls Township Water System

• 3 Well Fields
• Provides Service to Wholesale Customers
• - Hematite Township
• - Mastodon Township
• - City of Crystal Falls

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Some of the Challenges

• Schedule Majority of work needed to be
  designed, constructed and started up within 12
  months of the City/Township Agreement
• Coordination of Township project with on-going
  City Contractor
• Increasing capacity by three-fold to satisfy City
  demand.
• Start-up, disinfection of system tanks, wells,
  pumps and control systems.
• .and Deer Season.

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Project Components

• Three Separate Construction Contracts
• Contract I Water Storage Tanks
• Contract II Booster Pump Station/Wells
• Contract III Distribution System Piping

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Contract I - Taniks
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Project Components Continued

• Contract I Tanks
• New 500,000 gallon ground storage tank
• Rehabilitate 75,000 gallon Elevated North End
  Tank
• Rehabilitate 150,000 gallon Elevated Lind System
  Tank
• Demolition of 50,000 gallon Tank

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Contract II Booster Station and Wells
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Project Components Continued

• Contract II Booster Pump Station/Wells
• New Booster Pump Station w/(2) - 1,000 GPM pumps
• New North End Well/Controls/Well House Expansion
• New Lind System Wells/Controls/Well House
  Expansion

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Project Components Continued

• Kuivila Well House and Pump Improvements
• SCADA System Centralizing Controls from about a
  119 Square Mile Area
• - All Water System Controls and Operating Data
  Trending
• - Some Sewer System Controls and Operating Data
  Trending

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Contract III - Piping
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Project Components Continued

• Contract III Distribution
• 72,000 feet of new pipe
• 5,000 feet of directional borings (wetlands,
  streams, highways and railroads)
• New Customer Water Meters with Vehicle Equipped
  Automatic Radio Meter Reading Equipment

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Contract III Piping Continued
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Contract III Piping Continued
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Wells and Well House Construction Photos
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Expanded Lind Well House for New Well
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Lind Well House and New Well
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Expanded Townline Road Well House for New Well
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Ground Storage Tank Construction Photos
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Ground Storage Tank Inlet/Outlet Piping Designed
for Mixing
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New 500,000 Gallon Ground Storage Tank
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Pipe Laying Challenges
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Rock Excavation Along Highway US-2

• 6,500 cyd of rock removed on the project

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Rock Blasting/Dual Pipe Installation Through
Private Property
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Dual 16 Watermain Installation Rock/Groundwater
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Booster Pump Station Photos
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New Booster Pump Station
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Booster Pump Station Controls
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Townships US-2 Elevated Tank

• Receives Water from Ground Storage Tank from
  Booster Pump Station

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Booster Pump and Existing Elevated Tank
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The Death of Smiley

• ...he was a good tank

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Existing 50,000 Gallon Smiley Tank Replaced by
500,000 Gallon Ground Storage Tank
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The Death of Smiley
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.yes, a sad day...
but wait, Terry can fix em
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Smiley lives onon top of the New Ground
Storage Tank. A memento of the past
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Contract II New Radio Controls and SCADA System

• Uniquely Procured Prior to Bidding Project
• Contractors used Dollar Allowance on their Bid
  Form
• Hired Controls Integrator Selected by STS/Township

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Contract II Controls and SCADA System

• Provides Sustainable Design Features Integrated
  into Project.

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City Flow Control Valve and Controls
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City Master Flow Control Valve Assembly
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City Master Flow Control Valve Vault In Progress
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Existing Sewer Lift Station with New Radio
Integrated into Township SCADA System
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Dont let this relaxed, happy look fool you.
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Conclusion

• A Long Term Agreement and Cost Effective Solution
  Was Achieved by All Parties Involved, including
• Crystal Falls Township Customers
• Hematite Township Customers
• Mastodon Township Customers
• and Customers of City of Crystal Falls

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Conclusion Continued

• Funding Summary
• RD Grant 2.27M
• RD Loan 3.589M
• EPA Grant 386K
• Crystal Falls Township Road Fund 183K
• City of Crystal Falls 1.407M
• Hematite Township Road Fund 14,700
• Total Cost 7.85M

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The End
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Proposed Steps for Next Year

• Grant Application
• Wellhead Team Agreements Needed for Application
• Final Wellhead Delineation Report and Maps
• Contaminant Source Inventory
• Develop Wellhead Management Plan for existing and
  future wells
• 5. Development of a public education program

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Review of 2007 Draft Wellhead Delineation Report

• Surveyed existing wells and developed groundwater
  contour map (Potentiometric Surface Map).
• Conceptual Model
• To determine aquifer parameters
• Identified draft wellhead delineation areas.

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Lind System Potentiometric Map
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North System Potentiometric Map
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