WASTEWATER TREATMENT PLANT

MASTER PLAN

7. DESCRIPTION OF RECOMMENDED PROJECT

This chapter summarizes the recommended projects for upgrading the Napa Sanitation District
(District) Wastewater Treatment Plant (WWTP) to address existing deficiencies, improve
redundancy of key facilities, and add capacity. Proposed improvements would accommodate
growth and both existing and possible future, more stringent discharge requirements. The
improvements would also deliver more recycled water when needed to accommodate increased
demand.

7.1 Trigger Points for WWTP Improvements or Expansion

To respond appropriately to future changes, such as additional connections or changes in load
contributed by existing customers, the District needs to recognize what conditions could require
changes such as adding more WWTP components or upgrading existing components. The
District must also understand when a project must come online so that sufficient lead time to
initiate planning, design and construction can be established. Previous Wastewater Treatment
Plant Master Plan (Plan) chapters have defined existing capacity, capacity limitations, and
projects that would increase capacity. This section presents and discusses potential triggers for
District action. Section 7.2 describes a time range for project implementation. Later sections lay
out existing capacities and show triggers for changes. The reader should note that some WWTP
improvement projects are not triggered by future events but address current deficiencies
identified through master planning.
As stated above, many trigger points in the Plan, such as organic loading treatment or hydraulic
transfer, are linked to capacity. To establish a set of trigger dates within the Plan, planning
presented herein assumed that growth defined in the City and County General Plans would occur
over the next 20 years. If growth is delayed, the District would reach identified triggers at later
dates. Conversely, if growth occurs earlier than projected, capacity triggers would be reached
earlier. In addition, increasing wastewater strength without growth could also trigger projects
earlier. And if the District was to annex new areas with additional demands outside the existing
service boundary, the total ultimate required capacity would increase beyond that identified in
the Plan. Such a change would require new studies to define extra capacity needs in the WWTP
and how best to reach them.
Based on the recommended alternative, District staff and its consultants have identified several
potential triggers that require implementing major projects, e.g., new effluent filters. The Plan
specifically addresses these triggers, which include:
• Peak hour wet weather flow (PHWWF) capacity deficiencies.
• Increased influent biochemical oxygen demand (BOD) and total suspended solids (TSS)
loading.

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• Increased WWTP influent flows.

• Increased recycled water demand.
• Possible future regulatory changes to lower ammonia limits.
• Equipment redundancy for risk mitigation and maintenance purposes.
• Improvements to upgrade aging facilities to address equipment wear or deterioration.
• Improvements to enhance operations.
• District acceptance of fats, oils and grease (FOG); and winery wastes at the WWTP (added
to either or both the solids systems and oxidation ponds)
District staff and its consultants also recognize that factors beyond those listed above could lead
to new projects or new project triggers beyond those shown in the Plan. For example,
development not included in the City of Napa and/or Napa County planning documents could
lead to additional projects because construction could generate new sewage flows while
simultaneously increasing recycled water demands beyond the ultimate capacity defined in the
Plan. The District also could decide to accelerate planned projects because it could borrow
money at highly competitive rates, or it could take advantage of a favorable bidding climate
and/or available special grant funding.
The projected flows and loads developed in Chapter 2 served as the basis for the project trigger
charts. Future flow and load projections do not, however, dictate a specific calendar time frame
for implementing any portion of the Plan. The District will construct future treatment facilities as
needed in incremental stages over the planning period as it realizes or firmly projects actual
increases in wastewater flows and loads. Flow and load triggers to start new facilities are
established based on the lead time required to design and construct them, the projected growth
rate, and existing facilities capacity limitations. The District will track its flows and loads,
together with any regulatory changes and increased demands or contracts for delivery of recycled
water, and adjust the timing of expansion or upgrade projects accordingly.
Where the District currently has no basis for selecting timing, such as with recycled water
demand, capacity serves as a surrogate for calendar dates.

7.2 Implementation Activities

Implementation activities for any project include some or all of the following, with required time
as noted:
• Predesign Planning. This activity typically would take three to six months but could extend
to 18 months if a project requires pilot testing or full-scale demonstration. Some smaller
projects may not require any predesign activities, with detailed project definition occurring
during the design.
• Design. For smaller projects the design time could be as short as three months. Typical
design time would be nine to 12 months.
• Bidding and Award. The bidding and award time will vary depending on project size and
District requirements. Bidding typically requires one to two months, as does awarding,
depending on District Board schedules. Thus, this activity’s overall time frame is two to
four months.

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• Construction. Construction duration reflects construction complexity and lead time

required for key equipment. Typical durations range from six months or less for smaller
projects without specialty equipment to up to 20 months for a major project, possibly with
complicated tie-ins to existing facilities.
• Commissioning. Commissioning times vary widely from several weeks to several months.
For example, commissioning often includes substantial time for staff training; however,
none of the recommended projects defined through master planning include completely
new processes for which District staff would need such training.
• Environmental Review and Permitting. In general, Plan projects will be completed onsite
with little or no offsite impact, so little is expected for environmental review and
permitting. If the District determines that a project requires environmental review, related
activities could add between three to six months to the project schedule, although a
substantial portion of environmental review could occur in parallel with other predesign
activities. Most projects will require a negative declaration determination by the District
Board, which may require a public comment period of one month and adoption at a
subsequent meeting. Permitting will be minimal, though it should be noted that expanding
the recycled water system may require updating the Engineer’s Report for California
Department of Public Health and Regional Water Quality Control Board, San Francisco
Bay Region, which may require two to three months to review.
In summary, the District could implement smaller projects in as little as nine months, while the
most complex projects could take almost four years if the District needs to carry out detailed
environmental review. Preliminary estimated schedules for individual projects are presented later
in this chapter.

7.3 Capacity Triggers

Five potential project triggers discussed in Section 7.1 are capacity triggers. Because of the
parallel processes at the WWTP, these capacity triggers can require projects in different WWTP
areas. This section shows the capacity trigger charts, which indicate when projects must both
start and reach completion. Project descriptions in Section 7.4 include discussions of
implementation times for each project. The following sections describe each project by WWTP
area and include the trigger values to begin design. The District should track WWTP flows and
loadings against the trigger charts annually to reassess project timing.
7.3.1 PHWWF Trigger
The influent pump station (IPS) limits WWTP PHWWF capacity. The existing IPS has a reliable
(firm) capacity with one pump out of service of 25 million gallons per day (mgd), significantly
less than current peak flows as shown in Figure 7-1. Together, the downstream facilities (the
headworks and the diversion pipeline to the ponds) have the capacity to convey projected
PHWWF. Owing to the current, limited firm capacity, the District needs to initiate this project on
an accelerated schedule. The future PHWWF depends on the success of collection system
infiltration/inflow (I/I) improvements and capacity improvements. The District should monitor
PHWWF and trigger additional IPS projects if PHWWF increases further.

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Figure 7-1. Peak Hour Flow Triggers

PHWWF increases trigger projects. Dates shown represent projections.

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7.3.2 BOD Loading Trigger

The WWTP BOD capacity is limited by the combined pond and activated sludge capacity.
Several BOD loading scenarios were analyzed during the capacity and alternatives analysis,
including average dry weather maximum month BOD loading and average wet weather
maximum month (AWWMM) BOD loading. AWWMM BOD loading (the running 30-day
average of BOD loading) was found to be the limiting parameter. AWWMM BOD loading was
converted to average annual (AA) BOD loading using the loading relationships shown in
Table 2-13.
As shown in Figure 7-2, BOD loading triggers projects in different areas of the WWTP over the
planning period. Converting to step-feed is already underway. The District should monitor AA
BOD loading and trigger new projects based on Figure 7-2.
7.3.3 River Discharge Flow Triggers
River discharge flow is limited by flocculating clarifier, activated sludge, Pond 4 pump station,
and pond water direct filtration capacities. Analyses also considered secondary effluent pumping
and chlorine contact capacity and hydraulics. To control pond levels during wet weather, the
required river discharge capacity during wet weather was set to equal the AWWMM flow. Thus
whatever wastewater entered the WWTP would be treated and discharged. AWWMM flow was
converted to average dry weather flow (ADWF) using the relationships shown in Table 2-13.
Available river discharge flow is also shown for low influent flows when the activated sludge
flow is limited. Based on water balance results, these river discharge capacities are sufficient.
As shown in Figure 7-3, river discharge flow capacity triggers projects throughout the WWTP.
Some of these projects (new filters and aeration basin expansion) are expected to be triggered by
other factors (recycled water demand or loading) before river discharge flows would trigger their
construction.
7.3.4 Recycled Water Demand Triggers
Recycled water production capacity is limited by several processes, including filtration capacity,
disinfection capacity, and available secondary effluent flows. Projected recycled water demands
are not related to the growth-based influent flow and loading projections, but depend on District
addition of customers. The exact timing of the recycled water demand increases is beyond the
scope of the Plan; therefore, the chart shown in Figure 7-4 does not show project timing, but
illustrates the total capacity after each project. Figure 7-4 also shows the available recycled water
based on current ADWFs. The full capacity of many projects can not be used until ADWFs
increase. Latter sections discuss the lead time for each project. Projects that increase capacity are
shown in logical increments based on the existing facilities’ capacities, although future demands
may necessitate different phasing.
The existing filters are at capacity under current peak-day reclamation demands that occur during
dry weather (5.1 mgd). Since designing and constructing new filters may take almost four years,
an interim project to test whether filtration rates improve when flocculating clarifier effluent is
treated in the activated sludge process is shown. This full-scale pilot test only requires some

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piping modifications and has the potential to increase existing filter capacity until new facilities
are available. Results could be incorporated into the design of new filter facilities.
Chapter 2 discusses potential recycled water demands, including the peak recycled water
demands for various scenarios resulting from the water balance. To maximize water delivery
with current ADWF (median yearly supply of 3,700 acre-feet [AF]), a peak filter capacity of
11.0 mgd is required. With increased ADWF, required capacity increases to 12.1 mgd
(2020 ADWF; 4,000 AF). Since the District expects to maximize delivery as soon as possible,
the Phase 1 recycled water project is expected to be implemented immediately. Timing of the
Phase 2 project will depend on recycled water demand.
7.3.5 Solids Handling Demands
Solids handling capacity is limited by the digester. Projected sludge loadings are shown based on
influent flow and loading projections. Projected sludge loadings include both primary and waste
activated sludge based on process modeling results. Since primary sludge accounts for more than
60 percent of the projected sludge loading, an approximate relationship to AA TSS loading is
shown as the trigger for digester expansion. Projected sludge loadings do not include District
acceptance of non-traditional wastes. If non-traditional wastes are accepted, digester expansion
would be required sooner. Figure 7-5 shows projects triggered by AA TSS loading. Total sludge
loading is shown for reference; the Plan recommends that monthly digester loadings be
monitored also.
The District expects to add FOG to the digesters to increase gas production and optimize the
cogeneration engine operation (HDR Energy Study, 2010). The District’s objective would be to
add sufficient FOG so that the existing cogeneration system would generate power at its
maximum name plate continuous capacity. Existing digestion capacity would allow the District
to add about 3,000 pounds per day (lb/day) of volatile solids during maximum month loading
conditions.
7.3.6 Sensitivity Analysis
A sensitivity analysis has been performed to clarify the impacts to the recommended capital
improvement program (CIP) of development occurring at rates greater than and less than the
projected development rate in. The results show how slower or faster growth rates would impact
the phasing for major capital projects needed to increase the WWTP capacity and hence the CIP.
This sensitivity analysis shows the base scenario that follows the population and growth
assumptions developed for the Collection System Master Plan and carried over into the WWTP
Plan. It also shows a slow growth scenario—150 fewer equivalent dwelling units (EDUs) each
year and a fast growth scenario—150 more EDUs each year. Table 7-1 and Figure 7-6 present
the approximate start and completion dates for five major CIP projects for the three growth
scenarios. Figure 7-6 also indicates the approximate duration for the major projects, with the
duration rounded up to the nearest calendar year. With the slow growth rate the WWTP would
reach capacity in about 2036 compared to about 2030 for the Plan growth rate, and about 2026
for the fast growth rate.

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Table 7-1. WWTP Improvement Projects for Three Growth Scenarios

High Growth Low Growth
(150 EDU per year more (150 EDU per year less
Project Projected Growth than projected) than projected)
A Floc Clarifier Weirs 2011 – 2012 2011 –2012 2011 –2012
B Pond Aerators 2011 – 2013 2011 –2013 2017 –2019
C Phase 1 Filters 2013 –2018 2011 –2016 2017 –2022
D New Digester 2019 –2023 2017 –2021 2022 –2026
E Aeration Basin 2021 – 2025 2018 –2022 2025 –2029
Note: Project durations rounded up to whole years. Figure 7-6 shows project durations.

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Figure 7-2. BOD Loading Triggers

AA BOD Load increases trigger projects. Dates shown represent projections.

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Figure 7-3. River Discharge Flow Triggers

ADWF increases trigger projects. Required river discharge flow is assumed to equal AWWMMF in order to
maintain pond levels during a maximum month influent flow. Dates shown represent projections.

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Figure 7-4. Recycled Water Project Capacities

Recycled water from activated sludge is limited to the ADWF into the WWTP.
Available water for current ADWF shows potential recycled water production with current ADWF.
Capacity shows the installed capacity, which is equivalent to the available water at the 2030 ADWF.
Average yearly water supply capacity in AF is estimated based on the peak 30-day demand from the water balance model for the
10-year return frequency dry year, without any delivery curtailment.
Further delivery curtailment may be required during peak week demand conditions

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Figure 7-5. Solids Handling Triggers

AA TSS loading triggers projects. AA TSS loading does not include non-traditional wastes.
Monitoring monthly raw sludge load to the digester is recommended. Dates shown represent projections.

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Figure 7-6. WWTP Improvement Projects for Three Growth Scenarios

The figure shows project durations. Table 7-1 shows project start and completion dates.

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7.4 Project Description

This section describes the recommended projects and includes project triggers and
implementation time.
7.4.1 Influent Pumping
The IPS evaluation is based on the PHWWF pumping capacity into the WWTP. With one pump
out of service, the existing IPS has a reliable capacity of 25 mgd, significantly less than current
peak flows. Based on direction from District staff concerning planning for expected peak flows,
improvements to the IPS will increase capacity to pump the projected PHWWF through 2030
(60 mgd), as shown in Figure 7-1. The 60-mgd PHWWF depends on the success of collection
system I/I improvements and capacity improvements. According to the Collection System
Master Plan (Winzler & Kelly, October 2007), the PHWWF could be as high as 90 mgd, if
I/I improvements are not successful and collection system conveyance capacity constraints are
addressed so the peak flows from a 10-year storm reach the WWTP.
The recommended IPS expansion project includes constructing a new pump station adjacent to
the existing IPS with both dry weather flow and wet weather flow pumps. During the preliminary
IPS design more detailed analyses will determine whether the existing pump station structure
could be salvaged and reused only for pumping dry weather flows, to reduce overall project
costs. The project is described in the technical memorandum “IPS Seismic Study and
Replacement” (Winzler and Kelly, May 2009). The upgraded IPS would have a firm capacity of
60 mgd.
The IPS design will provide room for expanding the firm capacity to as much as 90 mgd in the
future. District staff will monitor how influent flows change as the District implements collection
system improvements and decide later whether to increase IPS capacity beyond 60 mgd. Note
that if the IPS is expanded beyond 77 mgd, the capacity of the pond diversion pipeline would
need to be increased to convey the additional flow.
The IPS project includes programming costs to automate the gate at Manhole 9 so that diversion
to Pond 1 during wet weather events can be controlled automatically through the WWTP
supervisory control and data acquisition (SCADA) system.
The IPS will require up to 48 months for permitting, design and construction, including:
• Six months for predesign.
• 12 months for design.
• Six months beyond design completion for environmental permitting.
• Four months for bidding and award.
• 20 months for construction and commissioning.
Since the IPS is already operating beyond reliable capacity, the project should begin immediately
and be completed by 2015.

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7.4.2 Headworks
The headworks improvement project would increase capacity to 20 mgd (existing capacity is
15.1 mgd) and address condition issues. The project includes:
• Replacing grit pumps, grit classifiers and washer compactors.
• Replacing screens.
• Increasing knife gate valve size on headworks hopper and modifying the hopper.
• Raising the headworks overflow weir.
Headworks improvements will require up to 25 months for design and construction, and include:
• Four months for predesign.
• Six months for design.
• Three months beyond design completion for environmental permitting.
• Three months for bidding and award.
• Nine months for construction and commissioning.
This project is triggered by the equipment’s age and condition. Based on wastewater industry
experience, the equipment is estimated to have a useful life of 15 to 20 years. Since it was
installed in 2001 and shows signs of significant wear, predesign should begin in 2014 to achieve
completion by 2016.
7.4.3 Primary Treatment
The primary treatment improvements include:
• Modifying the primary scum box piping.
• Lowering the primary diversion structure weir.
• Programming automatic primary scum pumps to shut off when high water levels are
reached in the primary clarifiers.
The primary treatment improvements would enhance operation and increase capacity to 20 mgd
(existing capacity is 17 mgd) and would require approximately 22 months for design and
construction, including:
• Four months for predesign.
• Six months for design.
• Three months beyond design completion for environmental permitting.
• Three months for bidding and award.
• Six months for construction and commissioning.
The primary treatment improvements are needed to improve system operation at high flows and
to enhance operation. Since the capacity increase can only be realized when headworks
modifications are also completed, predesign should begin in 2014 to achieve completion by
2016. This schedule matches the schedule for headworks improvements.

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7.4.4 Activated Sludge

Three different activated sludge projects are included, as described below. Because the activated
sludge system has already been converted to step-feed mode, that project is not described.
7.4.4.1 Diffuser Replacement and Programming Improvements
The diffuser replacement project includes:
• Replacing the activated sludge panel diffusers with a new type of diffuser that can transfer
more oxygen.
• Automating the air drop leg valves.
• Programming the blower aeration to address surge issues.
• Programming the return activated sludge (RAS) pumping to maintain a minimum RAS
flow.
• Adding mixers to aeration basin compartments as required based on additional analyses.
The diffuser replacement project will require approximately 25 months for design and
construction, including:
• Four months for predesign to determine best type of diffuser to meet oxygen transfer
requirements, especially given ongoing technological improvements.
• Six months for design.
• Three months beyond design completion for environmental permitting.
• Three months for bidding and award.
• Nine months for construction and commissioning.
This project is needed to improve activated sludge operation. A previous study (Carollo
Engineers, October 2008) identified the need to replace the existing diffusers with units that can
achieve higher flux rates and satisfy aeration demands year round. The process optimization
conducted during the Plan has confirmed that the existing panel diffusers are successfully
operating above their rated flux in some compartments, even though this mode will decrease the
life of the diffusers and reduce oxygen transfer efficiency. In 2008, the District replaced diffuser
membranes. The diffusers will reach the end of their useful life in five to seven years, at which
time replacement with a new diffuser system rated for a higher flux is recommended. For the
diffusers to be in place when the existing membranes reach the end of their useful life, predesign
should begin in 2011.
7.4.4.2 Additional Aeration Basin Volume
The aeration basin expansion project includes:
• Constructing a 0.66-million-gallon (MG) aeration tank, equal in size to Compartment
No. 6 of the existing aeration basins. The new basin will be designed for future expansion
(beyond the planning period) so that it also would function as part of a full third aeration
basin.
• Modifying the primary effluent and RAS piping and distribution to configure the activated
sludge system to operate in step-feed mode with the new aeration tank.

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After completing the aeration basin expansion and projects scheduled for earlier completion
(increase pond aeration, adjust flocculating clarifier weirs, expand Pond 4 pump station, and add
1,400 square feet of filters), the WWTP will have an AA BOD loading capacity of 23,400 lb/day
(8.6 mgd ADWF, based on flow and loading projections defined for the project) .
The aeration basin project does not include a new blower. The existing system includes two
high-speed turbine blowers and one standby multi-stage centrifugal blower. Together, the
existing high-speed blowers have sufficient capacity for the expanded aeration basin. The
District would continue to use the centrifugal blower as a standby.
The aeration basin project will require up to 40 months for design and construction, including:
• Six months for predesign to confirm that wastewater characterization and loading
requirements have not significantly changed since the time of this Plan.
• 12 months for design.
• 12 months for an Initial Study/Project Specific Environmental Impact Report, with six
months extending beyond design completion.
• Four months for bidding and award.
• 12 months for construction and commissioning.
Capacity needs would trigger this project. Based on current flow and loading projections, the
new aeration basin needs to be on line to accommodate loading increases when AA BOD loading
exceeds about 21,700 lb/day (approximately 8.0 mgd ADWF, projected to occur in 2025), or
when ADWF exceeds 8.0 mgd to accommodate river discharge capacity requirements
(approximately 2025). Thus, the District should track both ADWF and AA BOD loading and
their growth trends, since either parameter could trigger the project if future flow and loadings
differ from Plan projections.
For the aeration basin to be in service when the capacity is required, design should begin either
when AA BOD loading reaches about 20,200 lb/day or when ADWF reaches about 7.5 mgd.
7.4.5 Oxidation Ponds and Flocculating Clarifiers
The recommended project would include four different facultative pond and flocculating clarifier
projects, as described below.
7.4.5.1 Pond Improvements
Previous evaluation of the pond system (Brown and Caldwell, July 2008b) identified deficiencies
with the existing pond system, including failing or failed inlet structure and Pond 1 distribution
piping and transfer structures. Those analyses also defined and developed costs for proposed
solutions, which included new piping to allow recycling Pond 4 effluent to the Pond 1 influent
before coagulant is added to flow routed to the flocculating clarifier.
The pond improvements project includes:
• Replacing the inflatable plug on the Pond 1 pipeline with an isolation valve.
• Replacing the pond transfer structures.
• Replacing the Pond 1 inlet structure and distribution piping.

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• Replacing the existing aerators.

The District likely would divide this work into two phases, the first limited to replacing a couple
transfer structures between Ponds 1 and 2 as an immediate need, and the second for all other
work listed above.
The transfer structures, constructed of corrugated metal pipe in the late 1960s, no longer have
functioning control gates and have released odors caused by decomposing trapped algae. Based
on the Brown and Caldwell July 2008b Technical Memorandum, the recommended project
includes four new transfer structures between Ponds 1 and 2, and single transfer structures
between Ponds 2 and 3 and 3 and 4. Each transfer structure will have a manually set control
valve to allow the operators to control pond level. During the predesign for this improvement,
the District should explore options for inlet flow distribution and aerator type and locations. The
next addition is about 100 horsepower (hp) of replacement aeration capacity.
The pond improvements will require up 25 months for permitting, design and construction,
including:
• Four months for predesign.
• Six months for design.
• Three months beyond design completion for environmental permitting.
• Three months for bidding and award.
• Nine months for construction and commissioning.
The District CIP already includes pond transfer structure replacement scheduled for completion
by 2013. The District recently reconditioned the Pond 1 inlet structure. This work should extend
its service life by five to 15 years. Thus, the District needs to monitor the inlet structure
condition and schedule its design and new inlet facilities construction accordingly.
7.4.5.2 Flocculating Clarifier Weirs
The flocculating clarifier weir project raises the radial and effluent weirs by approximately
3 inches to increase the hydraulic capacity. Emphasis should be placed on confirming that weir
placements are accurately leveled during construction to help ensure an even flow split between
the clarifiers. The project also includes raising the scum boxes and skimmers.
With the flocculating clarifier weir project completed, the WWTP will have a river discharge
capacity of 21.3 mgd (equivalent to an ADWF of 7.3 mgd.)
The flocculating clarifier weir project will require up to 10 months for design and construction,
including:
• Four months for design.
• Three months for bidding and award.
• Three months for construction and commissioning.
This project is triggered by river discharge capacity needs. Based on current flows, this project is
needed immediately.

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7.4.5.3 Increase Pond Aeration

This project adds an additional 125-hp of aeration to the ponds to increase BOD loading
capacity.
After the pond aerators are installed, the WWTP will have an AA BOD loading capacity of
19,100 lb/day. The additional aerators increase AA BOD loading capacity by approximately
2,700 lb/day (5,600 equivalent dwelling units).
The pond aeration project will require up to 23 months for permitting, design and construction,
including:
• Three months for predesign.
• Five months for design.
• Three months beyond design completion for environmental permitting.
• Three months for bidding and award.
• Nine months for construction and commissioning.
This project is triggered by BOD loading capacity. Based on current loading projections, the new
aerators need to be on line when AA BOD loading exceeds about 19,100 lb/day (2014). Design
should begin when AA BOD loading reaches about 18,700 lb/day.
7.4.5.4 Phase 3 Recycled Water Expansion
The combined flow from activated sludge and the existing flocculating clarifiers can only
produce 12.6 mgd of recycled water. When peak day recycled water demand exceeds 12.6 mgd,
an additional flocculating clarifier is needed to produce flocculating clarifier effluent for
filtration. The Phase 3 Recycled Water Expansion project includes a third 80-foot-diameter
flocculating clarifier. Triggers and implementation for the Phase 3 Recycled Water Expansion
are described in Section 7.4.6.6.
7.4.6 Tertiary Treatment and Effluent Disinfection
Seven different projects are included to increase tertiary treatment and effluent disinfection
capacity and condition. These projects do not include possibly modifying the effluent diffuser in
the river to meet enhanced regulatory requirements, which the District is addressing outside the
Plan.
7.4.6.1 Tertiary Treatment Improvements
Tertiary treatment improvements include:
• Adding a motorized valve and associated programming and piping that would allow
District staff to select flow routing for secondary effluent.
• Replacing sand and airlifts in existing filters.

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Tertiary treatment improvements project will require up to 24 months for design and
construction, including:
• Three months for predesign.
• Six months for design.
• Three months beyond design completion for environmental permitting.
• Three months for bidding and award.
• Nine months for construction and commissioning.
Owing to equipment age and condition, the District should schedule this project for early
implementation.
7.4.6.2 Full-Scale Testing of Flocculating Clarifier Effluent to Activated Sludge
The existing filters are at capacity treating a blend of flocculating clarifier effluent and activated
sludge effluent. Even if the District added new secondary effluent equalization immediately, the
available recycled water would still be limited by low raw sewage influent flows. The Plan
includes new filters to increase recycled water capacity, but constructing new filters could take
about four years. An interim project is included to test whether filtration rates improve when
flocculating clarifier effluent is treated in the activated sludge process before filtration. The
assumption is that bioflocculation of the flocculating clarifier effluent in the activated sludge
system would improve filterability of the combined effluent so that a higher flow can be filtered
in the existing filters. This full-scale pilot test requires only piping modifications and has the
potential to increase existing filter capacity until new filters and equalization are constructed.
Results could also be incorporated into the design of new filter facilities.
The project includes:
• Temporary piping modifications to route a constant flow of flocculating clarifier effluent to
the activated sludge system.
• Consultant support to help prepare the testing plan and analyze results
Different flows will be tested throughout the project, starting with a small amount of flocculating
clarifier effluent and increasing the quantity with time. Adding a constant flocculating clarifier
effluent flow of up to 4 mgd to the constant primary effluent flows of about 4 mgd is potentially
feasible. The project would study both the activated sludge system performance with flocculating
clarifier effluent and the possible filtration rates.
This project has the potential to increase the recycled water peak day capacity to 7 mgd. The
timing of recycled water demand increases is beyond the scope of this Plan, but this project
could be implemented in the interim before the Phase 1 filter expansion is on line.
7.4.6.3 Phase 1 Recycled Water Expansion
The Phase 1 Recycled Water Expansion includes:
• A predesign study to optimize filters. The study should include a study of reject rates,
chemical doses, and media sieve size analysis.

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• Secondary effluent equalization. The pump station included as part of this project also
would allow the WWTP staff to route substandard activated sludge effluent to the
oxidation ponds.
• 1,400 square feet (sf) of filters.
• A chlorine injection and mixing system for the west chlorine contact basin so that all
chlorine contact volume can be used for recycled water production during peak demand
periods.
• An adjustable chlorine contact tank weir gate to relieve peak hydraulic limitations during
river discharge.
• Piping modifications to allow separate operation of the new filters on activated sludge
effluent or combined operation with the existing filters.
• Pond 4 pump station expansion.
The WWTP currently filters a blend of flocculating clarifier and activated sludge effluent at a
low loading rate (2.2 gallons per minute per square foot [gpm/sf]). With secondary effluent
equalization, the WWTP can filter all of the activated sludge effluent in the summer at a constant
rate. Since filter loading rates are higher with activated sludge effluent (4.2 gpm/sf), secondary
effluent equalization, followed by separate activated sludge filters, are included. The activated
sludge filters (Phase 1 – 1,400 sf) are sized to treat the full 2030 ADWF. At lower raw sewage
flows, there will not be sufficient flow to use the full filter capacity. When the Phase 1 filters are
completed, the recycled water available will be at least 11.1 mgd, with a maximum capacity of
12.8 mgd, assuming sufficient primary effluent flow is available.
In its current operating mode, the Pond 4 pump station reliable capacity is limited to about
8 mgd. This project rehabilitates and expands the Pond 4 pump station to 16 mgd total
capacity/12 mgd firm capacity. Hydraulic limitations in the chlorine contact tank limit capacity
to 22.7 mgd during river discharge (approximately 7.7 mgd ADWF) and 10 mgd during
reclamation. This project includes adding an adjustable weir gate on the chlorine contact tank
effluent to relieve these limitations and to increase capacity to 25.1 mgd during river discharge
(approximately 8.6 mgd ADWF), and at least 14.3 mgd during reclamation.
The Phase 1 Recycled Water Expansion project will require up to 50 months for design and
construction, including:
• 12 months for predesign.
• 12 months for design.
• Six months beyond design completion for environmental permitting.
• Four months for bidding and award.
• 16 months for construction and commissioning.
Analyses have identified two potential triggers for this project. The project needs to be on line
when peak day recycled water demands exceed the existing capacity of 5.1 mgd, although the
project could potentially be delayed based on the testing results described in Section 7.4.6.2 until
peak day recycled water demands exceed 7 mgd or 8 mgd. Since the District plans to maximize
recycled water supply immediately, the Phase 1 Recycled Water Expansion is needed

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immediately. The filters will also be used to increase river discharge capacity (triggered by
ADWF of 7.1 mgd).
7.4.6.4 Phase 2 Recycled Water Expansion
The Phase 2 Recycled Water Expansion includes:
• 600 sf of filters.
• A chlorine contact basin tracer/re-rating study.
The additional flocculating clarifier effluent filters (Phase 2 – 600 sf) increase filtration capacity
to match the existing flocculating clarifier effluent capacity. When the Phase 2 filters are
completed, the recycled water available will be at least 12.6 mgd, with a maximum capacity of
14.3 mgd, assuming sufficient primary effluent flow is available.
The Title 22 requirement for modal contact time is 90 minutes. Since field testing has not been
performed to determine the actual modal contact time, a conservative theoretical contact time of
120 minutes was used to account for hydraulic inefficiencies and to calculate the chlorine contact
tanks’ reclamation capacity. A tracer study can determine the effective detention time for the
contact tanks and, based on project team experience at similar facilities, the rated capacity is
expected to increase. Since the contact tanks have a capacity of 13.2 mgd at 120 minutes
theoretical contact time, it is expected that the rerating study can increase capacity to match or
exceed the Phase 2 peak capacity of 14.3 mgd.
The Phase 2 Recycled Water Expansion project will require up to 38 months for design and
construction, including:
• Four months for predesign.
• 12 months for design.
• Six months beyond design completion for environmental permitting.
• Four months for bidding and award.
• 12 months for construction and commissioning.
This project is triggered by recycled water demands and is not scheduled. The project needs to be
online when peak day recycled water demands exceed the Phase 1 Recycled Water Expansion
project capacity. This project should be considered when peak day recycled water demands
exceed 10.8 mgd.
7.4.6.5 Phase 3 Recycled Water Expansion
The Phase 3 Recycled Water Expansion includes:
• A new flocculating clarifier (see Section 7.4.6.4).
• 1,200 sf of filters.
• Additional disinfection capacity (i.e., a new chlorine contact tank, most likely near the
recycled water reservoirs).

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This project includes the facilities to expand recycled water capacity beyond the Phase 2 project.
The filter and disinfection facilities are sized to match the new flocculating clarifier effluent
capacity. The activated sludge filters are sized to treat the full 2030 ADWF, so at lower ADWF,
flows will be insufficient to use the full filter capacity. When Phase 3 is completed, the recycled
water available will be at least 15.7 mgd with a maximum capacity of 17.4 mgd, assuming
sufficient primary effluent flow is available to use the activated sludge filters fully.
The Phase 3 Recycled Water Expansion project will require up to 38 months for design and
construction, including:
• Four months for predesign.
• 12 months for design.
• Six months beyond design completion for environmental permitting.
• Four months for bidding and award.
• 12 months for construction and commissioning.
Recycled water demands will trigger this project. The project needs to be on line when peak day
recycled water demands exceed the Phase 2 Recycled Water Expansion project capacity. This
project should be considered when peak day recycled water demands exceed 12.6 mgd.
7.4.7 Recycled Water Storage and Pumping
The master planning and prior studies identified two needs for the recycled water system within
the WWTP boundaries—a jockey pump to deliver recycled water at lower demands and
additional recycled water storage.
7.4.7.1 Recycled Water Jockey Pump
A jockey pump study (Brown and Caldwell, May 2005) found that the recycled water system
might benefit by adding a 200-hp pump with variable speed control. The proposed pump is
considerably smaller than the existing 600-hp pumps. It would provide reliable capacity when
recycled water demands are lower. The District initially attempted to address this need by
running the existing 600-hp pumps at reduced speed; however, owing to system requirements
and limitations of the larger pumps, such operation causes adverse wear. Hence, current
conditions justify jockey pump installation.
This project will require up to 24 months for design and construction, including:
• Three months for predesign.
• Six months for design.
• Three months beyond design completion for environmental permitting.
• Three months for bidding and award.
• Nine months for construction and commissioning.
This project is needed to prolong the life and reduce maintenance costs of the existing pumps.
This project should begin immediately.

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7.4.7.2 Line Recycled Water Reservoir

As designed, the WWTP had two open storage reservoirs for tertiary effluent with a volume of
about 6.5 MG/20 AF and a surface area of 53,000 sf. To discourage algae growth and preserve
disinfection residual, the District subsequently added membrane covers and raised the height of
the side walls to increase storage potential. The covers are successful at maintaining water
quality, but to achieve the full storage increase, the reservoirs need membrane liners and minor
rework on the pump bases to create tight seals. With the modifications, the reservoirs would have
a capacity of 25 AF. This equates to one day of storage at an 8-mgd recycled water demand,
which is considered typical storage for a recycled water system.
This project will require up to 23 months for design and construction, including:
• Four months for predesign.
• Four months for design.
• Three months beyond design completion for environmental permitting.
• Three months for bidding and award.
• Nine months for construction and commissioning.
This project is triggered by additional recycled water storage capacity needs.
7.4.8 Solids Treatment
Two projects are recommended for solids handling.
7.4.8.1 Purchase Spare Digester Mixer
The spare digester mixer project includes:
• Purchasing a spare digester mixer to have available for quick installation should the
existing mixer fail. Design will include a plan for temporary operation and repair should
the existing mixer need to be replaced.
This project will require up to 10 months for design and construction, including:
• Two months for design and plan preparation.
• Eight months for procurement.
The District should purchase the spare mixer immediately to minimize the risk of a digester
failure. There is a greater risk of problems with the spare mixer approach than if a redundant
digester was constructed. For example, volatile solids reduction during digestion may be less
effective when the mixer is offline. Hence, District staff may not have dewatered solids that it
could immediately apply to District lands (at least not Class B biosolids). The District would
need to hold the dewatered solids for an extended period before land application; however, the
District has decided to assume that risk.

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7.4.8.2 Complete Egg-shaped Digester

The egg-shaped digester project includes:
• Converting existing half-egg digester to a complete digester.
• Constructing a 0.35-MG digested sludge storage tank.
• Constructing a separate gas storage tank.
This project will require up to 46 months for design and construction, including:
• Six months for predesign.
• 12 months for design.
• Six months beyond design completion for environmental permitting.
• Four months for bidding and award.
• 18 months for construction and commissioning.
This project is triggered by digester solids loading capacity. Based on current loading
projections, the new digester needs to be on line when digester solids loading exceeds about
27,000 lb/day (AA influent TSS loading of about 22,000 lb/day, assuming only primary and
waste activated sludge). Design should begin when digester solids loading reaches about
24,700 lb/day (AA influent TSS loading of about 20,500 lb/day).
7.4.8.3 Solids Handling Improvements
The solids handling improvements project includes:
• Replacing or upgrading the digester heat exchanger.
• Adding grinders for sludge circulation piping.
• Implementing gas storage volume programming for the Dystor.
This project will require up to 31 months for design and construction, including:
• Four months for predesign.
• Nine months for design.
• Three months beyond design completion for environmental permitting.
• Three months for bidding and award.
• 12 months for construction and commissioning.
This project is needed to enhance operations and should begin immediately.
7.4.8.4 Belt Filter Press Filtrate Equalization
The belt filter press filtrate equalization project includes:
• 0.3-MG filtrate equalization tank.
• 250-gpm filtrate equalization pump station.

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The filtrate equalization project will require up to 28 months for design and construction,
including:
• Four months for predesign.
• Eight months for design.
• Three months beyond design completion for environmental permitting.
• Four months for bidding and award.
• Nine months for construction and commissioning.
The District would only implement this work if future regulatory changes decreased allowable
WWTP effluent ammonia concentrations. This project’s objective is to equalize the high-
ammonia filtrate and nitrify it in the activated sludge system, which would significantly reduce
the pond ammonia loading and, hence, reduce ammonia in the pond effluent. The base Plan
projects were selected to meet a monthly average ammonia limit of 45 milligrams per
liter (mg/L). Based on historical pond effluent ammonia concentrations, the base project effluent
ammonia is expected to be less than 20 mg/L; therefore, an ammonia limit less than 20 mg/L
would trigger project consideration. The filtrate equalization system could be operational slightly
more than two years after the District receives a reduced ammonia limit.
7.4.9 Support Systems
Two support system projects were identified—maintenance shop and support building.
7.4.9.1 New Maintenance Shop and Support Building
A new maintenance shop and support building is needed to provide space for maintenance staff
and facilities.
This project will require up to 36 months for design and construction, including:
• Four months for predesign.
• 12 months for design.
• Six months beyond design completion for environmental permitting.
• Four months for bidding and award.
• 10 months for construction and commissioning.
7.4.9.2 3W System Improvements
The 3W system improvements project includes:
• Replacing and modifying 1W, 2W and 3W system piping to address corrosion and
dissimilar piping materials, and to add and/or replace isolation valves.
• Adding a variable frequency drive to second 3W pump.
This project will require up to 24 months for design and construction, including:
• Three months for predesign.
• Six months for design.
• Three months beyond design completion for environmental permitting.

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• Three months for bidding and award.

• Nine months for construction and commissioning.
This project is triggered by equipment condition and the need to enhance operations. This project
should begin immediately.
7.4.10 Maintenance Items
A number of other maintenance-related items were identified during the Plan. These items are
not included in the list of Plan projects. A list of these maintenance recommendations is included
in TM 11 – Alternatives Cost Estimate.

7.5 Capital Costs

Table 7-2 summarizes the capital costs and implementation details for the base Plan project.
More details on capital costs and cost estimating can be found in TM 11 – Alternatives Cost
Estimate.
Table 7-3 summarizes the add-on projects that are not part of the base project but may occur
during the planning period. Dates for these projects are unknown.

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Table 7-2. Base Project Implementation Summary

Capital Permitting, Design Project
Cost and Construction Completion
Project Million $1 Trigger to Begin Predesign Duration, months Priority2 Date
Flocculating Clarifier Weirs 0.6 ADWF of 6.8 mgd (2011) 10 A 2012
Full-Scale Testing of Flocculating Clarifier Peak day recycled water demand of 5.1 mgd and Phase 1 Recycled Water A
Effluent to Activated Sludge 0.3 Expansion not on-line NA 20123
Purchase Spare Digester Mixer 0.4 Redundancy – start in 2011 10 A 2012
Increase Pond Aeration (Add 125 hp) 2.2 AA BOD Load of 18,700 lb/day (2011) 23 A 2013
Recycled Water Jockey Pump 0.2 Reduce maintenance - immediate (2011) 24 A 2013
Activated Sludge Diffuser Replacement 0.9 Condition/age - start in 2011 based on useful life of existing equipment 25 C 2013
Pond Improvements – Phase 1 0.1 Condition/age - immediate (2011) 25 C 20134
Pond Improvements – Phase 2 2.8 Condition/age - immediate (2011) 25 A 20135
Tertiary Treatment Improvements 1.1 Condition/operational enhancements - immediate (2011) 24 C 2013
3W System Improvements 0.3 Condition/operational enhancement - immediate (2011) 24 C 2013
Solids Handling Improvements 0.8 Operational enhancements – immediate (2011) 31 C 2014
IPS Expansion 15.5 PHWWF of 25.0 mgd (2011) 48 A 2015
Four years before peak day recycled water demand exceeds 5.1 mgd A
Phase 1 Recycled Water Expansion 13.9 (2011) or ADWF of 7.1 mgd (2014) 50 2015
Line Recycled Water Reservoir 0.2 Recycled water storage needs 23 C 2015
Headworks Improvements 1.2 Condition/age - start in 2014 based on useful life of existing equipment 25 C 2016
Operational enhancements - Start in 2014 in parallel with Headworks C
Primary Treatment Improvements 0.3 Improvements. 22 2016
Maximum month sludge loading of 24,700 lb/day (approximately AA B
Complete Egg-Shaped Digester 11.4 influent TSS loading of 20,500 lb/day) (2019) 46 2023
Aeration Basin Expansion 4.2 AA BOD loading of 20,200 lb/day (2021) or ADWF of 7.5 (2021) 40 B 20256
Phase 2 Recycled Water Expansion 4.9 Four years before peak day recycled water demand exceeds 11.1 mgd 38 D -7
Base Project Total 61.3
1
Costs were determined for April 2010 for Napa, California, using the San Francisco ENRCCI (ENR construction cost index) of 9,730.
2
Priority A indicates projects required to accommodate capacity by 2016, projects critical for reliability of WWTP operations, and projects expected to save significant maintenance cost. Priority B projects
accommodate capacity increases after 2016. Priority C projects are mainly facilities condition/age related. Priority D projects are unscheduled.
3
Testing will take approximately one year, so results could be available by 2012.
4
Install transfer structures between Ponds 1 and 2.
5
Install replacement aerators, remaining transfer structures and distribution piping. The District may choose to delay some parts of this project, to reduce early expenditures. Aerator replacement is most
important.
6
Triggered by AA BOD loading increase. River discharge capacity required in 2025.
7
Project is triggered by peak day recycled water demand based on District plan to maximize recycled water delivery. Project timing will depend on recycled water demand.

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Table 7-3. Add-On Project Implementation Summary

Capital Permitting, Design
Cost and Construction
Project (millions) Trigger to Begin Predesign Duration, months

Belt Filter Press Filtrate Equalization Tank and Pumping 3.3 Regulatory — consider for monthly average ammonia limit less than 20 mg/L 28

Phase 3 Recycled Water Expansion 15.5 Four years before peak day recycled water demand exceeds 12.6 mgd 38

New Maintenance Shop and Support Building 2.0 Space for maintenance 36

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