Santa Ana Watershed Project Authority Inland Empire Brine Line Reach V Pipeline Condition Study Final Report Prepared by: May 10, 2013 May 2013 Table of Contents Executive Summary………………………………………………………………………..……………i ES-1 Purpose of Report………………………………………………………………….………i ES-2 Risk Assessment Findings……………………………………………..…………….….i ES-3 Project Recommendations………………………………………………………………ii ES-4 Summary of Project Costs…………………………………………………...…………iii Section 1 Introduction…………………………………………………………………..…………….1 Section 2 Background and Project Location………………………………………….………….1 Section 3 Existing Conditions along the Alignment……………………………………….……4 3.1 Geotechnical Conditions…………………………………………………………………...4 3.1.1 General Site Soil Characterization………………………………………………………..4 3.1.2 Existing Pipe Depth………………………………………………………………………...5 3.1.3 Test Pit Soil Data…………………………………………………………………...………6 3.1.4 Pipe Ovality………………………………………………………………………………….7 3.2 Existing Utilities……………………………………………………………………………..9 3.3 Land Use and Key Areas……………………………………………………..……….....10 3.4 Traffic and Roadway Usage……………………………………………………………..10 3.5 Environmental Factors……………………………………………………………………12 3.6 System Hydraulics…………………………………………………………………...……14 3.6.1 System Hydraulics Overview………………………………………………………….....14 3.6.2 Surge Analysis………………………………………………………………………...…..17 3.6.3 Reach V Existing System Hydraulic Characteristics……………………………....….17 Section 4 Risk Assessment Summary…………………………………………...………………22 4.1 Risk Based Approach…………………………………………………….………………22 4.2 Risk Assessment Results…………………………………………………………..…….23 Section 5 Rehabilitation Options Evaluated for Short and Long-Term Projects……...….31 5.1 Pressure Grouting…………………….…………………………………………………..31 5.2 Tight Fit HDPE Lining………………………………………………………………...…..32 5.3 Pipe Bursting………………………………………………………………………………32 5.4 Open Cut Replacement…………………………………………………………………..32 5.4.1 General Description…………………………………………………...………………….32 5.4.2 Construction Impacts………………………………………………….………………….33 5.4.3 Hydraulic Impacts…………………………………………………………………………33 5.5 Pressure Cured-In-Place Pipe Lining……………………………….…………………..34 5.5.1 General Description………………………………………………………………………34 5.5.2 Construction Impacts……………………………………………………………………..34 5.5.3 Hydraulic Impacts…………………………………………………………………………37 Section 6 Maintenance Access Structures, Isolation Valves, and Air/Vacuum Valves.…49 6.1 Maintenance Access Structures…………………………………………………………49 6.2 Isolation Valves……………………………………………………………………………49 May 2013 6.3 Air/Vacuum Valves………………………………………………………………………..51 Section 7 Near, Short, and Long-Term Project Recommendations……………...…………54 7.1 Recommendations Summary………………………………………...………………….54 7.2 Hydraulic Impacts…………………………………………………………………….…...61 7.3 Impact to Existing Utilities………………………………………..………………………61 7.4 Traffic Impacts…………………………………………………………………………….62 7.4.1 General Permitting Requirements…………………………………...………………….62 7.5 Residential and Commercial Impacts…………………………………………………..62 7.5.1 Local Traffic………………………………………………………………………………..62 7.5.2 Noise………………………………………………………….…………………………….63 7.5.3 Impacts to Local Businesses…………………………………………………………….63 7.6 Anticipated Construction Easement Requirements……………………………...……63 Section 8 Project Phasing and Implementation………………………………………………..64 8.1 Near-Term Maintenance Access Structure Installation Project…………………......64 8.1.1 Recommended Phasing………………………………………………………………….64 8.1.2 Brine Flow Management……………………...………………………………………….65 8.1.3 Anticipated Down Time for Customers…………………………………………………65 8.1.4 Construction Duration………………………………………… …………………………66 8.2 Short-Term Pressure CIPP Lining Rehabilitation Project…………………………….67 8.2.1 Recommended Phasing………………………………………………………………….67 8.2.2 Bypass Pumping…………………………………………………………………………..67 8.2.3 Anticipated Down Time for Customers……………………………………...………….68 8.2.4 Construction Duration…………………………………………………………………….68 8.3 Long-Term Pressure CIPP Lining Rehabilitation Project………………………….....69 8.3.1 Recommended Phasing………………………………………………………………….69 8.3.2 Bypass Pumping…………………………………………………………………………..69 8.3.3 Anticipated Down Time for Customers……………………………………………...….69 8.3.4 Construction Duration…………………………………………………………………….69 8.4 Overall Project Implementation Schedule……………………………………………...70 Section 9 CEQA Documentation…………………………………………………………………..72 Section 10 Construction Costs for Recommended Projects…………………………………..74 10.1 Accuracy………………………………………………..………………………………….74 10.2 Benchmark…………………………………………………………………………………74 10.3 Unit Cost Basis…………………………………………………………………………….74 May 2013 List of Tables Table ES - 1: Risk Assessment Results……………………………………………………………..i Table ES - 2: Summary of Project Recommendations……………………………….…………..ii Table ES - 3: Summary of Project Costs…………………………………………...………………iii Table 1: Compaction Test Results at 11 Test Pits……………………….……..….……..…..7 Table 2: Pipe Ovality Measured at 11 Test Pits……………………………………...…..…….8 Table 3: Summary of Current Daily Average Flows from EMWD Lateral………….…….14 Table 4: Summary of Pipe Segment by Contract…………………………………………....22 Table 5: Categorization of Risk Assessment Results…………………..……….……….…24 Table 6: Pressure CIPP Productivity………………………………………....………………...37 Table 7: Values Used in Calculating Pressure CIPP Lining Thickness………..……..….38 Table 8: Summary of CIPP Pressure Lining Impacts on the Brine Line…………..….….40 Table 9: Existing Air, Vacuum, and Combination Valves on Reach V of the Brine Line…………………………………………………………………………………………51 Table 10: Recommendations for Valve Retrofit or Replacement……………….………..…51 Table 11: Comparison of Existing and Recommended Air Release Valve Dimensions..53 Table 12: Known Existing Utilities in the Vicinity of Planned MAS Locations………...…61 Table 13: Construction Steps for Concurrent Installation of Two MAS Structures..……66 Table 14: Anticipated Construction Duration for Short-Term Pressure CIPP Lining Rehabilitation Project……………………………………………………………….…..69 Table 15: Anticipated Construction Duration for Long-Term Pressure CIPP Lining Rehabilitation Project……………………………………………………………..……70 Table 16: Summary of Estimated Conceptual Level Construction Costs for Near, Short, and Long-Term Projects……………………………………….………………….…..74 Table 17A: Near-Term Conceptual Level Construction Cost Estimate……………………..76 Table 17B: Maintenance Access Structure Cost Estimate Detail for Near-Term Project..……………………………………………………………………………….….77 Table 18: Short-Term Conceptual Level Construction Cost Estimate………………….…78 Table 19: Long-Term Conceptual Level Construction Cost Estimate…………...………..79 List of Figures Figure 1: Inland Empire Brine Line………………………………………...……………………2 Figure 2: Brine Line Reach V, Contracts II and III…………………………………………….3 Figure 3: Commercial/Roadway Development along Reach V in the Last 12 Years.......6 Figure 4: Contracts II/III Land Use and Key Areas……………………………..……………11 Figure 5: Flora and Fauna Habitat Areas along Reach V……………………………...…...13 Figure 6: EMWD Brine Line Lateral and Reach V Pipeline…………………………………16 Figure 7: Existing System, 3.25 MGD, Pressures on Reach II and III and Area of Concern Contract IV………………………………………………...…………....…..18 May 2013 Figure 8: Existing System, 3.25 MGD, Velocities on Reach II and III and Area of Concern Contract IV…………………………………………………………….…….19 Figure 9: Existing System, 11 MGD, Pressures on Reach II and III and Area of Concern Contract IV…………………………………………………………………………...…20 Figure 10: Existing System, 11 MGD, Velocities on Reach II and III and Area of Concern Contract IV………………..………………………………………….………………....21 Figure 11: Reach V High Risk Segment Project Drivers..……………………………………25 Figure 12: Basis for Recommended Short-Term Project, Contracts II and III………..….26 Figure 13: Basis for Recommended Long-Term Project, Contracts II and III……...…….27 Figure 14: Basis for Recommended Short-Term Project, Contract IV………..…………..28 Figure 15: Basis for Recommended Long-Term Project, Contract IV………..………...…29 Figure 16: Combined Long and Short-Term Projects, Contracts II, III, and IV……..……30 Figure 17: Access Pit Detail………………………………………………………………………35 Figure 18: Short-Term Project, 3.25 MGD, Pressures on Contracts II, III, and IV.…..…..41 Figure 19: Short-Term Project, 3.25 MGD, Velocities on Contracts II, III, and IV……..…42 Figure 20: Short-Term Project, 11 MGD, Pressures on Contracts II, III, and IV…..…......43 Figure 21: Short-Term Project, 11 MGD, Velocities on Contracts II, III, and IV…..….…..44 Figure 22: Long-Term Project, 3.25 MGD, Pressures on Contracts II, III, and IV.…...…..45 Figure 23: Long-Term Project, 3.25 MGD, Velocities on Contracts II, III, and IV…...……46 Figure 24: Long-Term Project, 11 MGD, Pressures on Contracts II, III, and IV……….....47 Figure 25: Long-Term Project, 11 MGD, Velocities on Contracts II, III, and IV…………..48 Figure 26: Maintenance Access Structure Detail………………………………….………..50 Figure 27A: Approximate Planned Location of Maintenance Access Structures, Isolation Valves, and Access Tees Contracts II and III…………………………………….55 Figure 27B: Approximate Planned Location of Maintenance Access Structures, Isolation Valves, and Access Tees Contracts II and III…………………………………….56 Figure 27C: Approximate Planned Location of Maintenance Access Structures, Isolation Valves, and Access Tees Contracts II and III…………………………………….57 Figure 27D: Approximate Planned Location of Maintenance Access Structures, Isolation Valves, and Access Tees Contracts II and III…………………………………….58 Figure 27E: Approximate Planned Location of Maintenance Access Structures, Isolation Valves, and Access Tees Area of Concern, Contract IV…..………..………….59 Figure 27F: Approximate Planned Location of Maintenance Access Structures, Isolation Valves, and Access Tees Area of Concern, Contract IV……………………….60 Figure 28: Potential Construction and Permanent Easement Locations…………………64 Figure 29: Overall Suggested Implementation Schedule for Near, Short, and Long-Term Projects……………………………………………………………..73 Appendices Appendix A - Summary of Utility Information Appendix B - Final Reach V Surge Analysis Report Appendix C - Detailed Breakdown of Risk Assessment Results Appendix D - Inventory of Existing Air Valves on Reach V Appendix E - Cost Estimate Unit Cost Criteria May 2013 May 2013 May 2013 Santa Ana Watershed Project Authority Inland Empire Brine Line Reach V Executive Summary Pipeline Condition Study Project FINAL Executive Summary ES-1 Purpose of the Report On October 18, 2011, a brine spill was reported on Reach V (Contract II and III) of the Inland Empire Brine Line (Brine Line) near the intersection of Temescal Canyon Road and Cabot Road in the City of Corona. The condition of the pipe in this location raised concern over the quality of construction and structural integrity of the entire Reach V pipeline with specific emphasis on Contracts II and III where the spill was located. The purpose of this Condition Study is to provide a pipeline condition study of Reach V (Contract II and III) and other known areas of concern in Contracts IV and V including a risk assessment and surge analysis. This study will define the limits of needed repair work and recommend appropriate rehabilitation and/or replacement methods for specific locations of highest risk along the alignment. In addition, a budgetary construction cost estimate is provided for the recommended alternatives to allow SAWPA to prudently budget the work. ES-2 Risk Assessment Findings A risk based approach was used in order to prioritize condition assessment and capital improvement project (CIP) activities. The total Risk per pipe segment was calculated by summing up the Likelihood of Failure Factor scores and multiplying that number by the weighted Consequence of Failure Factor scores. The result was a risk score per pipe segment. The resulting risk scores were then categorized based on risk value and placed in the following categories: Table ES-1. Risk Assessment Results Length of Pipe in Length of Pipe Contracts in Contracts IV Risk Risk CIP Project Project II and III and V areas of Total Length Category Score Definition Timeline (ft.) concern (ft.) of Pipe (ft.) Short-Term High Risk >= 50 Project (1) 0-3 years 11,954 876(3) 12,830 Medium Long-Term Risk >=20<50 Project (2) 4-10 years 6,334 1,873(3) 8,207 Low Risk <20 No Project N/A 8,353 11,404 19,757 Total: 26,641 14,153 40,794 (1) In order to facilitate construction packaging, some medium and low risk pipe segments were added to the short-term project. (2) In order to facilitate construction packaging, some low risk pipe segments were added to the long-term project. (3) Numbers shown are for area of concern in Contract IV only. There are no required projects for the area of concern in Contract V. May 2013 i Santa Ana Watershed Project Authority Inland Empire Brine Line Reach V Executive Summary Pipeline Condition Study Project FINAL ES-3 Project Recommendations Table ES-2 provides a summary of project recommendations for Reach V, Contracts II and III as well as areas of concern in Contract IV. Please note that no projects were recommended for the area of concern in Contract V. Recommendations were developed based on: 1. A risk assessment as is described in Section ES-2; 2. A surge analysis of Reach V; and 3. A rehabilitation alternatives analysis including a hydraulic analysis of the existing and future rehabilitated Brine Line Table ES-2. Summary of Project Recommendations Project Anticipated Schedule Description Near-Term  Install 26 Manhole Access Structures Manhole Access  Install 26 Plug isolation valves Structure Prior to Short-Term Project  Install 26 Access tees for future bypass pumping Installation Project  Pressure CIPP Line approximately 12,000 feet of 24-inch PVC pipe in Reach V, Contracts II and Short-Term III Pressure CIPP Within 3 years from start of  Pressure CIPP Line approximately 900 feet of Lining Fiscal Year 2013/2014 24-inch PVC pipe in Reach V, Contract IV Rehabilitation  Replace or modify 11 existing air release valves Project (CLA-Valve and ARI models)  Pressure CIPP Line approximately 6,300 feet of 24-inch PVC pipe in Reach V, Contracts II and Long-Term III Pressure CIPP 4-10 years from the start of  Pressure CIPP Line approximately 1,900 feet of Lining Fiscal Year 2013/2014 24-inch PVC pipe in Reach V, Contract IV Rehabilitation  Replace or modify 45 existing air release valves Project (Crispin and Valmatic models) In developing these recommendations, the evaluation included consideration of factors such as:  Impacts to upstream dischargers  Construction impacts  Adjacent utilities  Flow by-pass requirements  Environmental impacts May 2013 ii