2013 Racine Water Utility Annual Report

Transcription

2013
Racine Water Utility
Annual Report
Board of Waterworks Commissioners
Mayor John Dickert
Alderman Ronald D. Hart
Alderman James Morgenroth
Thomas Bunker
Kathleen DeMatthew
John Engel
Esther Helding
Keith E. Haas – General Manager
Michael L. Gitter – Chief of Operations
Ken Scolaro – Administrative Manager
Chad Regalia – Chief Engineer
Michael J. Kosterman – Plant Superintendent
Table of Contents
Title Page
Table of Contents ............................................................................................................................ 1-2
Letter of Transmittal ........................................................................................................................ 3
Mission Statement ........................................................................................................................... 4
Section 1
Racine Water Utility Personnel & Staffing .................................................................. 5
Racine Water Utility Organization ....................................................................... 6
2013 Racine Water Utility Personnel ................................................................... 7
2013 Personnel Summary ..................................................................................... 8
Section 2 Capital Improvement Projects ....................................................................................... 9
2013 Minor Capital Improvement Projects .......................................................... 10
2013 Major Capital Improvement Projects........................................................... 11-12
Section 3 Water Accounting & Efficiency Programs .................................................................... 13
Leak Detection...................................................................................................... 14-15
Large Meter Testing Program............................................................................... 15
Automated Meter Reading.................................................................................... 16
Summary .............................................................................................................. 16
Section 4 Utility Service Costs & Optimization ............................................................................ 17
2013 Residuals Management/Sanitary Services Summary................................... 18-21
2013 Electrical Services Summary ....................................................................... 22-23
2013 Natural Gas Services Summary ................................................................... 24-25
Section 5 Water Treatment Optimization Summary ..................................................................... 26
2013 Report on Filter Backwashing Optimization ............................................... 27
2013 Membrane Optimization Efforts .................................................................. 28-29
2013 Operations Cost Reduction Summary.......................................................... 30
Section 6 Water Production, Wholesale Customers, and Water Rates .......................................... 31
Water Production and Pumping Operations ......................................................... 32-34
Wholesale Customer Water Demand and Revenue .............................................. 35
Residential Trend in Water Consumption ............................................................ 35-36
Racine Water Utility Water Rates 1992-2013 ...................................................... 36
Section 7 Water Treatment Chemicals Information ...................................................................... 37
Water Treatment Chemical Costs & Usage .......................................................... 38
Recent Historical Water Treatment Chemical Use ............................................... 38-39
Section 8 Racine Water Utility Finished Water Quality................................................................ 40
Finished Water Quality Report ............................................................................. 41-46
Racine Waterworks Recent Historical Water Quality .......................................... 47-49
Section 9 Racine Water Utility Training and Safety ..................................................................... 50
Professional, Technical, & Safety Training .......................................................... 51-53
Reportable and Lost-Time Accidents ................................................................... 53
Section 10
Racine Water Utility Departments ............................................................................. 54
Operations Department ......................................................................................... 55-56
Maintenance Department ...................................................................................... 57-58
Meter Department ................................................................................................. 59-60
Construction Department ...................................................................................... 61
Engineering Department ....................................................................................... 62-65
[1]
Appendices ...................................................................................................................................... 66
Racine Water Utility Historical Milestones ........................................................... 67-69
Racine Water Utility Flow Schematic ................................................................... 70
Racine Water Utility Pretreatment Flow Schematic ............................................. 71
Racine Water Utility Potable Flow Schematic ...................................................... 72
Service Area and Pressure Zones .......................................................................... 73
2013 Consumer Confidence Report ...................................................................... 74-75
[2]
Letter of Transmittal
To:
Keith E. Haas, General Manager
Racine Water & Wastewater Utilities
Submitted herewith is a detailed annual report of the Waterworks Treatment Plant and Distribution System for the
year 2013.
Respectfully Submitted,
Michael L. Gitter
Chief of Operations
Michael J. Kosterman
Water Plant Superintendent
Kenneth M. Scolaro
Administrative Manager
James Moss
Operations Supervisor
Chad Regalia
Chief Engineer
Richard King
Maintenance Supervisor
Amy Lesnjak
Meter Supervisor
Mark Carr
Construction Supervisor
Robert R. Gilbreath
Technology Supervisor
[3]
MISSION STATEMENT
Our Mission is to provide the public
with safe, pure drinking water. The
completion of this mission, while
maintaining our tradition of costeffective operations, requires the
bringing together of each employee’s
individual work effort to form a team
effort.
To maximize individual
effort and teamwork, we strive to
develop a work environment that
recognizes the value of individual
differences, and fosters teamwork
and productivity among the diverse
and talented people who make up
our organization.
EXECUTIVE STAFF:
Keith E. Haas, P.E.
General Manager
Michael L. Gitter, P.E.
Chief of Operations
Chad Regalia, P.E.
Chief Engineer
Kenneth Scolaro, C.P.A.
Administrative Manager
Michael J. Kosterman
SUPERVISORY STAFF:
James A. Moss
Richard King
Amy Lesnjak
Meter Supervisor
Mark Carr
Construction Supervisor
Robert Gilbreath
[4]
Section 1
Personnel
&
Staffing
[5]
Racine Water Utility Organization
2013 Board of Waterworks Commissioners
Mayor John Dickert, Alderman Ron Hart, Alderman James Morgenroth, Thomas Bunker, Kathleen DeMatthew, John Engel, Esther Helding
GENERAL MANAGER
Keith Haas
EXECUTIVE SECRETARY
Nancy Sanders
CHIEF OF OPERATIONS
Michael Gitter
TECHNOLOGY SUPERVISOR
Robert Gilbreath
CHIEF ENGINEER
Chad Regalia
CONSTRUCTION
SUPERVISOR
Mark Carr
WATER PLANT SUPERINTENDENT
Michael Kosterman
ADMINISTRATIVE
MANAGER
Ken Scolaro
OPERATIONS
SUPERVISOR
MAINTENANCE
SUPERVISOR
METER
SUPERVISOR
James Moss
Richard King
Amy Lesnjak
CIVIL ENG. II
Jeff Guttenberg
ASST. ADMIN.
MANAGER
Susan Cryer
LABORATORY STAFF
Joan Pepin
Amelia Salinas
Crew Leaders
Jerome Cannon
Mark LaRue
CLERICAL
STAFF
CONSTRUCTION
STAFF
ENGINEERING
STAFF
OPERATORS
STAFF
MAINTENANCE
STAFF
METER
STAFF
Jerome Cannon
Eric Dahlke
Steve Filip
Anthony Johansen
Jeff Larsen
Mark LaRue
Joe Sullivan
John Ulcek
Endel Williams
Dirk Zimmer
Jim Garbedian
Mark Helmin-Clazmer
Brent Nimz
James Draper
Dave Brack
Howie Fors
David Brueggeman
Ty Chacon
Tom Clemens
Tim Otto
Pedro Rodriquez
Brad Schimian
Mike Weisbrod
Joe Cacciotti
Pete Georgeson
Rodney Harris
Ken Morgensen
Tory Prudhomme
William Roszkowski
Troy Schmidt
Kevin Wanggaard
Ed Trudrung
Kim Navis
Thomas Egresi
Robert Kaplan
David King
Todd Kramer
Dan Pociask
Tammie Rach
Joseph Ricchio
Ken Sands
Mike Wurster
[6]
Tracye Dyess
Ariadna Martinez
Kim Navis
Terri Edmonston
Diana Felix
2013 Racine Water Utility Personnel
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
Name
Brueggeman, David
Cacciotti, Joseph
Cannon, Jerome
Carr, Mark
Chacon, Tyrone
Clemons, Thomas
Dahlke, Eric
Draper, James
Egresi, Thomas
Filip, Steve
Garbedian, Jim
Georgeson, Peter
Gilbreath, Robert
Guttenberg, Jeff
Harris, Rodney
Helmin-Clazmer, Mark
Johansen, Anthony
Kaplan, Robert
King, David
King, Richard
Kosterman, Michael
Kramer, Todd
Larsen, Jeffrey
LaRue II, Mark
Lesnjak, Amy
Morgenson, Ken
Moss, James
Navis, Kim
Nimz, Brent
Otto, Timothy
Pociask, Daniel
Pepin, Joan
Prudhomme, Troy
Rach, Tammie
Regalia, Chad
Ricchio, Joseph
Rodriquez, Pedro
Roszkowski, William
Salinas, Amelia
Sands, Ken
Schimian, Bradley
Schmidt, Troy
Sullivan, Joseph
Trudrung, Edwin
Ulcek, John
Wanggaard, Kevin
Weisbrod, Michael
Williams, Endel
Wurster, Michael
Zimmer, Dirk
Brack, Dave
Fors, Howard
Position
Operator IV
Mechanic I
Construction V
Construction Superintendent
Operator I
Operator IV
Construction IV
Engineering Aide II
Meter II
Construction I
Engineering Tech I
Mechanic I
Engineer II
Mechanic III
Engineering Tech II
Construction I
Meter IV
Meter V
Meter I
Construction II
Construction III
Meter Supervisor
Mechanic III
Clerk/Dispatcher
Engineering Tech II
Operator I
Meter I
Water Resource Chemist
Mechanic III
Meter I
Chief Engineer
Meter I
Operator IV
Electrician
Laboratory Technologist
Meter I
Operator IV
Mechanic III
Construction II
Mechanic III
Construction III
Mechanic III
Operator IV
Construction I
Meter V
Construction IV
Construction Inspector
Construction Inspector
Longevity (Years)
23
16
12
14
10
16
6
6
12
16
24
25
14
7
26
22
1
24
23
28
26
11
7
9
24
12
26
16
17
17
<1
25
18
1
15
1
29
9
11
2
10
17
5
24
11
24
13
6
18
6
Part Time
Part Time
[7]
WDNR Licenses
Surface, Distribution
None
Distribution
Distribution
None
Distribution
None
Distribution
None
Distribution
Distribution
Distribution
Distribution
Distribution
Distribution
Distribution
Distribution
None
2013 Personnel Summary
Currently, the RWU employees 50 full-time people at the Hubbard Street facilities, not counting administrative staff
located at the City Hall Annex. As seen below, Table 1-1 breaks down the years of service distribution in the
Utility’s workforce and attaches the percentage of that group to the total employment.
Combining the last 2
columns, 30% of the Utilities workforce possesses 20 or more years of service. In 2014, 29 of 50 employees or
58% of the Utility’s workforce is or will be 50 years old or more. Throughout the country, concerns have been
expressed regarding the aging workforce and the pending retirements of “baby-boomers”. That same concern
applies to the Utility.
Table 1-1
Years of Service
Number of
Employees
% of Workforce
<5
5-9
10-14
15-19
20-24
> 25
5
9
11
10
8
7
10%
18%
22%
20%
16%
14%
During the past year, the Utility workforce stabilized relative to the previous year. The Racine Water Utility (RWU)
incurred no retirements or personnel transferring to other departmental positions in 2013. In early 2013, the Utility
filled the Meter I position, open from the previous year due to the personnel changes in 2012, by hiring one new
individual, Daniel Pociask.
January 1, 2013 marked a major change in union/management relationships. With the passage and execution of
Acts 10 and 32, along with the expiration of the last ASCME Local 63 negotiated labor contract on December 31,
2012, a new era in labor/management interactions began. The State legislation now prohibits negotiating with
representative employees for anything other than “base wages”. The Racine Water Commission approved and
implemented the “Policy Manual for Racine Water Utility Employees” on December 18, 2012 to define specific
work rules, policies, procedures; replacing articles as previously delineated in the expired Contract. This Policy
Manual applies generally to all Water Utility personnel as all employees are now categorized as “at-will”
employees. Additionally, work rules and policies instituted by the City of Racine continue to apply to all RWU
employees, as they do to all City non-represented employees.
[8]
Section 2
Water Utility
Capital
Improvement
Projects
[9]
2013 Minor Capital Improvement Projects
Service Building Boiler
Doors and Windows
The RWU replaced the 30+ year old boiler, a unit with limited life span,
increasing maintenance costs, and a lower efficiency. New boiler unit
reduces natural gas usage and provides better uniform heating.
The Utility schedules replacement of aging infrastructure throughout its
facilities. The door installations improve aesthetics, security, and insulation
value.
Budget: $40,000
Cost: $39,600
Budget: $5,000
Cost: $4,095
New Service Building Boiler
Door at Service Building Front Entrance
Service Building Roof Access Door
_________________________________________________
LED Lighting
________________________________________________
Utility Vehicles
The Utility continues to conduct staged replacement of lighting fixtures
throughout the facilities, aiming to reduce electrical use for building lighting.
Utility vehicles are replaced based on age, condition, and maintenance costs.
The RWU is systematically replacing its older fleet with more fuel efficient
vehicles to reduce overall fuel usage and costs.
Budget: $20,000
Cost: $20,000
Service Building Offices
Budget: $125,000
Cost: $103,422
Machine Shop
Meter Shop
Emergency Truck #8
Truck #1
________________________________________________
Sedimentation Basin Decant Valve Automation
Membrane Plant Permeate Vacuum System
The new equipment replaces the original installed equipment, reducing
electrical demand, lowering maintenance costs, and improving reliability.
Vacuum system provides vacuum for all 7 permeate pumps to sustain
filtering operations.
Work continued in 2013 to automate outdoor valves used in treatment
residuals management. Treatment basins 3, 4, and 5 are used to store
accumulated solids collected from basins 1 and 2. Solids separate
from the water. Weekly, the clarified water is decanted from the
storage basins and recycled for re-treatment. The basin 3 decant valve
was automated in 2013, enabling operators to open and close the valve
from the control room, eliminating the need to manually open the
valve.
Budget: $10,000
Cost: $11,107
Budget: $13,000
Cost: $5,740
Vacuum Pump & Receiver Tank
_________________________________________________
HVAC – Backwash Motor/VFD Room
The new HVAC equipment replaces a single window unit air conditioner.
The system maintains proper ambient temperatures in the Backwash
Motor/VFD room to prevent damage to electrical components
Electrician Installing Power & Control Wiring
Budget: $13,000
Cost: $10,056
Rooftop HVAC Unit
Automated Basin 3 Decant Valve
[10]
2013 Major Capital Improvement Projects
Backwash Pumps Variable Frequency Drive Upgrade
The RWU installed the existing filter backwash variable frequency drive system (VFD) used to control the rate of flow for
conventional backwashing in 1995. The equipment manufactured and supported by Rockwell Automation (Allen-Bradley)
reached the end of its useful life cycle over 2 years ago. Parts were no longer available and technical support no longer exists.
In 2013, contractors continued the VFD replacement project. The project, budgeted at $1.5 million, includes installing a 480v
transformer and switchgear, 3 new backwash pump motors with 1 surface wash motor, 4 VFD drives, and the staged
rehabilitation of the 3 backwash pumps and 1 surface wash pump. The project is scheduled to be finished in 2014.
New Transformer and Switchgear
Installation of Rehab Pump
4 New Medium Voltage VFDs
New Pump Motor
Completed Installation of Rehabbed Pump #3
Rebuilt Surface Wash Pump & New Motor
2013 Water Main Replacement Program
Introduction
Since 1986, the RWU conducts a yearly water main replacement program. Under the direction of the Utility Engineering
Department, contractors perform water main replacements in coordination with local, county, and state pavement replacement and
streetscape projects.
In 2013, the Engineering Department oversaw some 11,375 feet (2.15 miles) of water main replacement at a total cost of
approximately $1,877,000. For the 2013 projects, the RWU specified and installed PVC (plastic) water main for all the water main
replacement projects within the RWU distribution system.
Refer to the Engineering Department section of this report for more information regarding water main replacements and
installations.
W-13-1
Water Main Replacement - Phase 1
Locations:
N Memorial Drive (Albert to St Patrick)
Kewaunee Street (N Memorial to Carlisle)
Cherry St (leads)
Elm Street (leads)
English Street (leads)
Length & Size:
1,850’ of 8” PVC water main
19 New copper services (Lead replacements)
Contractor:
Earth X, LLC
Estimated Cost: $285,000
Actual Cost:
$235,000
__________________________________________________________________________________________________________
[11]
W-13-2
Locations:
High Street (Green to Erie)
Vista Drive (Spring Valley to Harrington)
Graham Street (Carmel to Mohr)
Dekoven Avenue (leads)
Mitchell Street (leads)
Length & Size:
Contractor:
AW Oakes and Sons, Inc.
Estimated Cost: $330,000
Actual Cost:
$372,000
__________________________________________________________________________________________________________
W-13-3
Locations:
Ruby Avenue (Shoreland to Dena)
Jackson Street (LaSalle to Douglas)
Grange Avenue (16th to 17th)
West Lawn Avenue (Blue River to 21st)
Russet Street (19th to 21st)
19th Street (Russet to Kentucky)
Kearney Avenue (Bate to 21st)
Lawndale Avenue (STH “32” to Sheridan)
Kenilworth Avenue (STH “32” to Sheridan)
Athaleen Avenue (STH “32” to Sheridan)
Length & Size:
850’ of 12” PVC water main
150 Service reconnections
Contractor:
AW Oakes and Sons, Inc.
Estimated Cost: $1,160,000
Actual Cost:
$1,270,000
[12]
Section 3
Water Accounting
& Efficiency
Programs
[13]
Leak Detection
The Utility began its own in-house Leak Detection Program in the spring of 2011,
with the purchase of a digital leak surveyor. This device is an acoustic amplifier,
which allows the user to pick up the sound of even the slightest leak in the area.
Dozens of leaks were found in 2011 with the leak surveyor, though actually
pinpointing the exact location of each leak was labor intensive. It was decided that
more advanced equipment was needed to make leak detections more efficient and
precise.
The Department took the next step in its leak detection efforts and purchased a digital
Cracked pipe found via Leak Detection
leak correlator in early 2012. A correlator listens and records the noises caused by
leaks at several points in the system, and then calculates the exact locations of the leaks based of time differentials.
Leak detection was performed intermittently throughout the year, as time permitted. Roughly 50% of the entire system has been
checked for leaks since 2011. At this rate, the entire system should be completely checked in another 3 years, at which point the
department will then start a second round of leak detections throughout the entire system.
49 leaks were found and repaired in 2013, which, if left untouched, would have accounted for lost water at a rate of approximately
90 million gallons per year. See the summaries below.
Leak Type
Count Potential Loss (GPY)
Hydrant Leak
2
1,051,200
Inside Service
20
10,512,000
Joint Leak
1
525,600
Outside Service 17
13,140,000
Pipe Crack
9
63,072,000
[14]
The map below shows the areas checked for leaks, to date.
Through the first 3 years, the leak detection program theoretically reduced lost water at a rate of over 317 million gallons of water
per year or approximately 868,000 gallons per day based on a totalized calculation. For 2013, the volume of leaking water detected
and stopped equates to a retail cost of approximately $250,000 annually. Theoretically, this program reduced unaccounted water by
1.5% in 2013. Additionally, this proactive approach towards searching for and repairing leaks ultimately reduces costs to repair
mains, hydrants, valves, and services. Allowing leaks to continue, worsens conditions and costs for labor, materials, and property
restoration work.
Large Meter Testing Program
In 2013, the Meter Department continued its effort, time, and funding to test, repair, or replace large meters (meters > 3”). Underreporting large meters, because of the large water volumes, have a significant financial impact on both the Water and Wastewater
Utilities. With new Public Service Commission regulations addressing ”unaccounted water”, there is now a greater emphasis to
lower percentages of this water category for compliance purposes. Meter personnel tested, changed, and/or serviced 71 large meters
in 2013, focusing on governmental and school sites. The RWU continued its program, first initiated in 2011, to photo-document
large (3” and above) meters in the system as demonstrated in the pictures below. This record keeping will prove that on the date of
inspection, the by-pass line was secured (chained, locked and tagged by Meter Dept. personnel) and the high and low meter side
reads manually recorded. These recorded meter readings are necessary since for billing purposes, the Orion system only provides a
summed read (high and low) total.
Meter Testing Program Photo-documentation
[15]
Automated Meter Reading (AMR)
The Wisconsin Public Service Commission (PSC) requires water utilities to replace each residential meter once every 20 years.
Personnel continuously monitor, remove, and replace meters in the multitude of vacant/abandoned properties, in addition to
scheduled meter replacements. The key problem of the old “Read-O-Matic” meter reading technology is the actual numerical
difference between the inside (base) meter and the outside register. This difference results in under-reporting of water use and
ultimately lost revenues for the RWU. For the 2013 meter replacement program, the Utility calculated differences between the
actual meter and the outside recorder readings, which totaled approximately 37.04 million gallons (4,952,400 ft3) of unreported
usage, equaling about $104,991 in potential lost revenue. This lost volume and revenue created by the inside/outside differences
will be recouped in accordance with PSC policies and regulations from the customers. The RWU, several years ago, changed to
automated meter reading (AMR) based on radio transmitters and receivers. Personnel using computers automatically communicate
directly with the customer’s water meter. The AMR system eliminates this differential problem, increases meter reading accuracy,
and makes meter reading less labor intensive. By the end of 2013, approximately 56% of the Utility’s nearly 34,000 meters now
employ AMR.
Reading Old-Style ROM
Residential Meter with
Radio Transmitter (Orion)
Radio Meter Reading with
Truck Mounted Computer
Radio Meter Reading with
Handheld Computer
Summary
In the production of potable water, some portion of water production never reaches the customers’ services because of pipe leaks or
is inaccurately measured by the customers’ meters. This category of water not metered or lost is called unaccounted water. The
PSC now requires water utilities to maintain their unaccounted water at less the 15% of their production. If water utilities cannot
reduce below this level after a specified number of years, these utilities must implement programs to reduce their percentage of
unaccounted water. The RWU’s unaccounted for water in the recent past had reached or surpassed the PSC threshold (Table 3-2).
Recognizing the need for action, the RWU voluntarily implemented a leak detection program in 2011 and has made this program an
on-going standard operating procedure. In the same time frame, the Meter Department re-emphasized its large meter testing
program and invested more capital funds to purchase and install replacement meters, all in order to more accurately measure water
consumption. In the 3 full years of these enhanced water accounting procedures, the leak detection program conservatively found
and eliminated 317 million gallons of leaks in the distribution system. In the same time frame, the meter replacement program
found 99 million gallons of under-metered water. For 2013, the RWU’s unaccounted for water amounted rose slightly to 11.2% of
treatment plant water production, but still well below the 15% threshold. The implementation of the leak detection program over
the last 3 years, the increased large meter testing, and replacement and conversion of residential meters to AMR, continues to prove
very successful and worthwhile.
Table 3-2
Year
% Unaccounted
for Water
2007
2008
2009
2010
2011
2012
2013
12.6
12.5
17.4
13.7
16.2
9.5
11.2
[16]
Section 4
Utility Service Reports
Costs & Optimization
Residuals Management (Sanitary)
Electric
Natural Gas
[17]
2013 Residual Management/Sanitary Services Summary
Introduction
Beginning in 2008, the RWU implemented significant operational changes to reduce the Hubbard Street facilities’
discharge to the sanitary sewer system, thus dramatically reducing costs. The 3 major changes made were: recycling
of laboratory sampling waters to the head of the plant (reducing pump station sanitary discharge), on-site dewatering and landfilling of water treatment solids, and recycling of filter backwash to the incoming raw water
(eliminated discharge to sanitary system).
Sanitary Pump Discharge Reduction
Formerly, the lab sampling faucets ran continuously with the discharge running to the sanitary sewer system. With
the completion of the laboratory remodeling, the sample water discharge is routed to the retention basin with sidestream sampling to the sample taps themselves. This configuration guarantees fresh samples for testing and
eliminates significant amounts of water to the sanitary sewer, thus saving the RWU significant sanitary charges. As
seen from Graph 4-1, water to the sanitary sewer system in 2013 decreased from 2009 by nearly 13 million gallons.
Monetary savings from this modification are included in the total wastewater services cost reduction.
Graph 4-1
Treatment Basins Solids Removal
This year (2013) marked the sixth year the RWU eliminated or curtailed treatment solids residual disposal via the
wastewater system and, instead, employed contractual services for its annual solids dewatering program. For the
first time in five years, the Utility experienced a decrease in the amount of solids sent for landfilling and an overall
decrease in total amount of solids produced from the course of water treatment. The decrease in solids production
can be attributed to the reduced volume of water processed in potable water production for 2013.
Graph 4-2 shows the estimated residual treatment solids generated by pretreatment of lake water and stored in the
sedimentation basins. The contractual price for this service totaled $148,751 for 2013. If the Utility had not
conducted onsite dewatering and, instead, sent this waste down to the Wastewater Utility, the cost would have been
roughly $223,250, thus saving the RWU approximately $74,499 in wastewater charges just for annual basin
cleaning. Of note for 2013, 807 less tons of solids were landfilled this year compared to 2012, and the actual
contractual cost decreased by $50,697 from 2012 to 2013. This cost savings included the one-time cost of $18,449
for clean-out and landfilling of the solids removed from the backwash water cistern.
[18]
Graph 4-2
2013 Wastewater Service Costs
The overall 2013 residuals management cost increased by $53,056 from 2012 as seen in Graph 4-3. The Racine
Wastewater Utility sanitary service charges portion increased to $140,258 from $76,691 in 2012. The 2013 O&M
budget figure for residuals management was set at $285,000, while the actual expenditure was $347,644.
The
RWU came in $62,644 over budget for 2013. Three reasons explain the increase wastewater costs for 2013. First, a
faulty hour meter on the main sanitary lift station was replaced, increasing the totalized annual flow up by 5 million
gallons ($20,000). Second, as seen in graph 4-2, a larger mass of solids (177 tons) was transferred to the sanitary
sewer system instead of being pressed and landfilled. This increased mass of solids transfer resulted from the staff
drawing down each individual basin and pumping directly to the sanitary sewer instead of diverting the discharge to
basin 3. RWU staff, using this method, attempted to reduce the risk of possible taste and odor carry-over into the
process waters. Third, contractors removed and disposed of the accumulated solids the backwash water cistern. The
cistern cleaning was attempted for the first time in over 25 years.
Graph 4-3
Historical Perspective
Looking at the annual wastewater service cost from a long-term perspective (Graph 4-4), the current (2009-2013)
dollar outlays are roughly on par to what the Utility paid in 1994. In 1994, the RWU experienced 2 “boil water
notices”. The aftermath of these incidents and resulting plant audits by regulators and consultants led to the
discontinuation of backwash recycling, and instead, diverting backwash water to the sanitary sewer system. As seen
in Graph 4-4, this resulted in immediate and steep increases in wastewater charges. Over the years, as sanitary
[19]
treatment fees increased, so did the service cost to the RWU. Off course, just raw dollars do not tell the whole story.
Graph 4-5 illustrates the cost of wastewater services as a percentage of the total annual operational and maintenance
expenses. With the re-implemented practice of backwash recycling and the onsite dewatering of treatment
sediments since 2008, the Utility reduced the percentage of wastewater service cost back to levels experienced from
the late 1970s through the 1980s, and into the early 1990s before the treatment upsets of 1994. As background to
understand treatment residual (wastewater services) practices, see below.
1926 - 1977:
1977 - 1994:
1994 - 2008:
2008 - Present:
All backwash water and accumulated treatment solids flushed back directly to Lake Michigan.
All backwash water recycled to head of plant. Treatment solids pumped to wastewater.
All backwash water and treatment solids pumped to wastewater.
All backwash water recycled to head of plant. Treatment solids dewatered onsite and hauled
offsite for landfilling.
Graph 4-4
Graph 4-5
Effects to Wastewater
Graph 4-6 illustrates the financial affect to the Racine Wastewater Utility, due to the cost reduction efforts at the
RWU. Revenues from Water Utility operations for the Wastewater Utility peaked at over $1 million in 2007. In
four years, revenues dropped to just under $45,000 in 2011, but increased significantly back to over $180,000 in
2013.
[20]
Graph 4-6
As seen in Table 4-1, the RWU achieved substantial reduction in wastewater service costs due to the operational
changes described above. When one uses the more conservative 3-year average, the Utility still decreased
wastewater service costs by about $621,619 for 2013. As described earlier, 3 operational changes implemented
since 2008 account for the majority of monetary savings.
1.
2008:
2.
2008:
3.
2010:
The RWU ceased pumping backwash water to wastewater and began recycling the
backwash water.
The RWU ceased sending treatment basin solids to wastewater, dewatered the solids
and disposed of these solids in a landfill.
In December, the RWU plumbed its laboratory sample lines to the retention basin
and eliminated this constant flow (10 - 15 million gallons per year) to wastewater.
These achieved savings continue into the future and may be enhanced as the Utility staff improve dewatering
practices and possibly lower other sanitary discharge volumes.
2007 Wastewater
Service
Charge
3-Year
Average (05-07)
Wastewater Service
Charge
$1,090,734
$969,273
Table 4-1
2013
Wastewater Service
Charge
2013
Wastewater Service
Savings
2013 Wastewater
Equivalent Charge for
Residuals
(solids, BOD, PO4,
etc)
$743,090
$223,245
$621,629
On-site Solids Dewater Savings
$74,499
$347,644
Using 2007
Value
Using 3Year
Average
Value
[21]
2013 Electrical Service Summary
Discussion
Electricity remains an essential element for water treatment and conveyance. Potable water production, on any
scale, is impossible without it. Electrical usage represents one of the largest costs in a water utility budget. Over the
last several years, the RWU incorporated a number of measures to reduce operational electrical demand and
procured special contracts with WE Energies to conserve on electrical usage and control costs. In 2013, the Utility
continued existing programs and operational practices to save costs and efficiencies.
With the expansion of treatment practices and buildings at the Hubbard Street campus (2003-2005), the construction
of two additional booster pump stations (2004 & 2006), and the acquisition of the Sturtevant Water Utility in 2007,
electrical use and costs rose in those years. In 2013, WE Energies implemented the Public Service Commission
approved rate hike, raising electrical costs for the RWU, while the Utility experienced a decrease in energy
consumption in 2013 compared to 2012.
In 2013, the RWU used approximately 8.277 million kilowatts to treat and supply water to the distribution system.
Electrical costs for the treatment plant and the distribution system totaled $783,282 while the Utility budgeted
$850,000 for electricity in 2013. Compared to 2012, the RWU saw a usage decrease of 772,000 kW and an overall
cost decrease of $36,497. These decreases can be attributed to lower production and lowered water demand in 2013.
In order to compare the efficiency of operations with regard to electrical use, the amount (kW) of electricity used in
a time period is divided by the total amount of water produced and pumped out of the treatment plant. The resulting
kW/MG value can then be compared from month to month and year to year. In 2013, the Utility averaged 1,369
kW/MG. Graph 4-7 illustrates the annual kW/MG since 1990. In 2013, the kW/MG value increased slightly from
previous years due to decreased volume of water flowing through the plant. The significant increase in 2006
resulted from the startup and fulltime operation of the membrane plant.
Graph 4-7
[22]
RWU Electrical Energy Efficiency Programs
Electrical use and costs comprise a significant portion of the Utility's operating budget. The RWU staff, over the
years, implemented a number of cost-saving programs and operational procedures all in an effort to reduce electrical
usage and contain energy costs. Four programs listed below summarize the cost-saving measures.
I.
Time of Day Electrical Use
Graph 4-8
The RWU receives lower electrical rates for each kilowatt it
uses during off-peak hours (10:00 PM - 10:00 AM weekdays)
compared to on-peak hours (10:00 AM - 10:00 PM
weekdays). The kilowatt charge for peak hours is $0.0735
compared to $0.0503 for off-peak hours. The RWU performs
more energy demanding operations, such as higher water
production pumping, filter backwashing, etc. at night. This
mode of operation, although not new for the Utility, was reemphasized in 2011. The higher the ratio of off-peak versus
on-peak, the more savings the Utility realizes. As seen in the
Graph 4-8, the RWU achieved substantial improvements in
off-peak energy use raising the ratio from 1.70 to 1.94. This
ratio increase equates to over $12,700 in annual savings.
________________________________________________________
Graph 4-9
II.
Interruptible Contract (CPFN)
The RWU contract for interruptible power with WE Energies
provides for another major electrical cost savings. This
agreement allows the commercial electrical supplier (WE
Energies) to interrupt (cut-off) power to the RWU for a
specified number of hours per day, and a certain number of
hours per year. In return, this contract reduces the cost of
kilowatts to the Utility both for on-peak and off-peak usage,
along with the near halving of the monthly demand charge.
Over the 8.5 years of this program, as seen in Graph 4-9, the
Utility reduced electricity costs by over $1.1 million.
______________________________________________________
________________________________________________________
III. LED Lighting
The Utility embarked on a program to replace its
incandescent, fluorescent, and metal-halide light fixtures with
light emitting diodes (LED) systems. Each year the RWU
appropriates $20,000 for purchase of LED lights and conducts
staged light replacements. Capital payback in energy savings
is estimated to be 3 to 4 years. LED lights use substantially
less energy compared to all other types of lights and have a
longer life-span.
___________________________________________
LED Light Fixture
________________________________________________________
IV. Equipment Out-of-Service
The RWU completed numerous major capital projects over
the last 2 decades. One result of these improvements was an
expansion of treatment plant capacity. This “extra” capacity
allows the Utility to shut down portions of different treatment
processes for extended portions of the year (low water
demand periods). The RWU routinely shuts down mixing
equipment in 3 of its 5 treatment basins for 8 to 9 months
each year. One-third of the filter beds are removed from
service for 5 to 6 months of the year. Estimated electrical
savings are in excess of 230,000 kilowatts or approximately
$12,500 per year.
[23]
Basin 3 Motor/Mixer (1 of 3)
Basin 4 or 5 Motor/Mixer (1 of 2)
2013 Natural Gas Summary
Introduction
Natural gas costs represent another significant portion of the RWU operation and maintenance budget. At the
Utility, natural gas is used for running the boilers for building heat, heating water for domestic use, drying air used
in three dehumidification systems in the treatment plant and membrane filtration building, natural gas heaters at
remote sites, and laboratory uses. As the Utility grew in number of buildings, the use of natural gas increased.
In 2013, the RWU budget contained a line item amount of $180,000 for natural gas. Actual 2013 costs totaled
$117,504.77 for all the facilities at the Hubbard Street complex and all the remote sites (booster pump stations,
elevated tank buildings, garage, etc.) as seen in Table 4-2.
Table 4-2
Filter Plant & Pump Station
Gas Transportation Costs
Membrane Plant, Service Building,
Generator Station & Remote Sites
$61,154.94
$9,316.31
$47,033.52
Graph 4-10 shows the amount of therms used each month in 2013 and the monthly costs for the main building
(filter plant and pump station). Significant reductions in gas usage annually begin in May and continue into
October. As standard operating procedure, the Maintenance personnel turn off the boilers in the Treatment Plant
and Service Building to conserve energy use since heating is usually not required during the late spring, summer,
and early autumn. The Utility still uses natural gas in the warm months to operate dehumidification systems to
produce dry air which keeps corrosion of pipes and equipment down to a minimum during the higher humidity
months. The pattern of gas costs and usage seen in Graph 4-10 obviously repeats itself at all the other facilities
using natural gas heat.
Graph 4-10
Graph 4-11 shows the annual natural gas usage since 1998 for the treatment plant and pump station. Natural gas
usage declined significantly after 2003. In 2004, the Utility installed new dehumidification equipment and initiated
the standard operating procedure of decommissioning the boilers in the warm weather months. This accounts for
most of the therm reduction seen in the last eight years. The natural gas consumption and cost increase for all
facilities in 2013 from the previous year, resulted from the lower climatic temperatures.
[24]
Graph 4-11
In order to account for the affects on climate conditions on natural gas consumption when comparing one year to the
next, the RWU now uses data supplied by WE Energies detailing the total number of heating degree days for each
billing period since 1998. By dividing the yearly therms used by the total heating degree days (HDD), the Utility
developed a comparative unit of measurement: therms/HDD. Graph 4-12 shows the annual therms per HDD from
1998-2013, and also plots the changes in efficiency the Utility achieved from one year to the next. Graph 4-12
illustrates 2004 and 2005 have the largest increases in efficiencies, due to the boilers being turned off during the
warm weather months. In 2009, the Utility improved the efficiency of boiler operations another 7.3% due to the
installation of the new gas burner with VFD controls and less use of the larger 300 horsepower boiler. In 2013, the
efficiency slightly increased and the therms/HDD value decreased to 16.6, the second lowest value in the last 16
years.
Graph 4-12
[25]
Section 5
Water Treatment
Optimization
Summary
[26]
2013 Filter Backwashing Optimization
Introduction
The RWU employs poly-aluminum chloride for water clarification treatment. Since the onset of this chemical
treatment in February 2008, the RWU optimized operations in different facets to reduce costs. The chemical
change allowed the Utility to increase conventional filter efficiency and obtain major operation benefits and
significant cost reductions. This section details the results of filter operations.
A. Length of Run (LOR)
C. Backwash Volume
Graph 5-1 shows the annual average LOR for the past
8 years. In 2013, the RWU achieved its highest filter
length of run in its history, maintaining a stable,
relatively high length of run compared to pre-2009
values.
As the number of backwashes decrease, so does the
overall volume of water used for backwashing. The
volume of backwash water in 2013 was 71.568 million
gallons (Graph 5-3). This represents a decrease of
75.91 million gallons (from 2007) or nearly 4.6 days
of finished water production. Based on the current
electrical and chemical costs, the RWU reduced
operational costs by $8,947 in 2013, due to backwash
decreases resulting from modified chemical treatment.
All other fixed costs (personnel, building, etc.) are not
reduced.
Graph 5-1
Graph 5-3
B. Filter Backwash Number
In 2013, the number of filter backwashes totaled 644,
relatively the same as the 3 previous years and over a 50%
reduction in backwash number from 2007 and before. The
backwash trend-line basically follows the historical decline
in water production with the past 5 years’ larger decrease
due to the chemical coagulant change implemented in
February 2008, as designated by the red arrow in Graph 52.
D. Percent of Production
Dividing total backwash volume by the total volume of
water treated provides for the term backwash as percent of
production. The lower the percent of production, the more
efficient filtering operations are. Graph 5-4 shows the last
5 years have significantly lower values compared to pre2008 levels. This again corresponds to the change in
chemical treatment.
Graph 5-2
Graph 5-2
Graph 5-4
[27]
2013 Membrane Optimization Efforts
Introduction
The desire to improve membrane filter operations provided the impetus to change coagulant chemicals (ferric sulfate
to poly-aluminum chloride) in 2008. The purpose was to reduce or eliminate iron carryover from the conventional
treatment plant to the membrane plant, decreasing the fouling mechanism for the membrane fibers. Reducing
fouling rates would theoretically reduce trans-membrane pressure, lower permeate pump speeds (= lower electricity
use), and decrease the need to chemically clean the membrane fibers.
This chemical change proved beneficial in treatment practices and cost reduction. It has been no different regarding
membrane plant operations. After the change in coagulant was made, permeabilities increased, showing the
reduction in fouling. Graph 5-4 presents permeability results as an average. The results become obvious as to the
positive affect of poly-aluminum chloride on the reductions of fouling rates.
Graph 5-4
With improvements in permeability (= lower trans-membrane pressure and lower fouling rates), the frequency for
performing chemical clean-in-place (CIP) procedures also declined. As seen in Graph 5-5, the 2013 CIPs again
totaled 29, the same as 2012. Looking at the actual CIP clean interval over the course of membrane operations,
the chemical cleaning interval increased to 90 days (using the PACl coagulant) from 39 days (using the ferric sulfate
coagulant). The RWU reduced its cost by $11,197 on membrane chemicals in 2013 from 2007 based on reduced
chemical cleaning frequency and current chemical prices.
Graph 5-5
[28]
As mentioned previously, the coagulant change resulted in lower fouling rates and lower operating trans-membrane
pressure. With a lowered operating pressure, the permeate pumps run at lower speeds, thus using less electricity.
This electrical reduction and any other electrical savings in the operation of the membrane plant are captured in the
lower kilowatts/million gallon calculations as delineated in the electrical service summary report (page 24).
[29]
2013 Operational Cost Reduction Summary
Table 5-1
Process Description
Peak Year*
Amount
2013
Amount
Reduction
From Peak
Year
Wastewater Service Charge Reduction
$1,090,734
$347,644
$743,629
1,393
1,369
kW/MG Electrical Use & Reduction
Average Kilowatts/Million Gallons
Kilowatts X off-peak 66.7% X $0.05025 X 6,044,617 MG
24
$4,862
Kilowatts X on-peak 33.3% X $0.07353 X 6,044,617 MG
$3,552
Backwashing Volume & Reduction
Million Gallons of BW Water
147.478
71.568
75.910
Calculated Savings in Produced Water based
Electrical Costs (1369kW x MG x $0.05025)
$5,222
Chemical Costs ($353,197 x MG /6,044,617)
$4,105
$12,500
$12,700
Equipment Out-of-Service Electrical Savings
Time of Day Electric Usage Optimization
WE Cp2M Contract Savings (Jan. 1 - Dec. 31, 2013)
$104,674
Leak Detection Program
2013 Estimated Volume = 90 MG
Calculated Savings in Produced Water based
Electrical Costs (1369kW/MG x 90 MG x 66.7% x $0.05025)
Electrical Costs (1369kW/MG x 90 MG x 33.3% x $0.07353)
$4,130
$3,017
Chemical Costs ($353,197 x 90 MG /6,004,617)
$5,259
12 (leaks on mains, valves, or hydrants) x $1,225 (repair cost savings)
17 (leaks on outside services) x $625 (repair cost savings)
$14,700
$10,625
Plant Natural Gas Consumption & Reduction
Membrane Plant Cleaning Optimization
Reduced Chemical Cleans
$122,828
$70,471
$52,357
228,579
119,030
109,549
59
29
2013 Total Amount of O&M Dollars Saved from Operational, Equipment, and Contractual
Changes
*Peak Year
Wastewater Service Fee
kW/MG
Backwash Volume
Natural Gas Dollars
Natural Gas Therms
2007
2006
Average 2005-2007
2008
2000
[30]
$11,197
$992,529
Section 6
Water Production,
Wholesale Customers,
Residential Use,
& Water Rates
[31]
Water Production and Pumping Operations
Table 6-1 below gives the 2013 monthly flow data for both the raw water and finished water pumping operations.
Maximum production for the month, highest daily average, and highest minimum day occurred in August, and
maximum day in September. Minimum production for the month occurred in February, while minimum day
occurred in March. Lowest daily average and lowest maximum day occurred in January.
Table 6-1
2013 Raw Water Data
Monthly
Total
Daily Avg.
MG
MGD
January
425,670
13731
February
399,413
14265
March
437,622
14117
April
433,449
14448
May
508,133
16391
June
573,022
19101
July
691,305
22300
August
724,772
23380
September
674,481
22483
October
510,353
16463
November
438,585
14620
December
443,330
14301
Raw Maximum Day:
September 11, 2013
Raw Minimum Day:
March 6, 2013
Daily
Max.
MGD
14905
16023
15606
18721
20312
22733
28419
28743
31857
20530
16660
15541
2013 Finished Water Data
Daily
Min.
MGD
12865
12850
12368
12987
12846
15689
15792
19638
15671
12969
12802
12785
Monthly
Total
Daily Avg.
MG
MGD
413,127
13327
386,280
13796
422,653
13634
418,941
13965
488,691
15764
550,626
18354
667,473
21531
700,219
22588
652,724
21757
488,186
15748
422,888
14096
432,809
13962
Finished Maximum Day:
Finished Minimum Day:
Daily
Max.
Daily Min.
MGD
MGD
14582
12535
15291
12630
14811
12144
17962
12605
19100
12608
21808
15028
27263
15249
27513
19021
15303
30380
19973
12331
15511
12523
15104
12625
September 11, 2013
March 6, 2013
As seen in Graph 6-1, a general downward trend in water production continued in 2013. Graph 6-2 takes the flows
presented in Graph 6-1 and shows the percentage change (+ or -) and the degree of the change from the previous
year. Four years show a positive change and ten years show a negative change. Water production in 2013
decreased 9.53% from 2012. Some decline in production probably resulted from the Utility’s aggressive leak
detection and repair program, but the majority of the decline resulted from all customers’ categories simply using
less water. During the time span of 2000-2013, water production decreased 27.5%.
Graph 6-1
Graph 6-2
[32]
Table 6-2 breaks down the ten-year period of 2004-2013 on a monthly basis and provides an average for each
month. The first 8 months in 2013 saw lower water production than 2012 and 2011 when new low water production
records were set! In 2013, ten months set the low monthly production mark for the last 50 years!
2004
2005
2006
2007
2008
Table 6-2
2009
2010
2011
2012
2013
Jan
587,744
543,736
539,676
555,089
566,313
551,411
504,671
476,261
453,253
413,127
10 Year
Average
519,128
Feb
580,362
494,267
490,727
523,076
539,549
515,741
460,857
439,120
409,628
386,280
483,961
Mar
614,994
549,045
553,447
586,822
576,270
576,307
509,688
479,969
436,927
422,653
530,612
Apr
614,963
565,690
561,819
572,671
567,054
565,943
475,633
457,498
430,282
418,941
523,049
May
649,124
611,215
638,523
677,394
667,706
623,690
571,405
522,277
524,526
488,691
597,455
Jun
723,912
829,478
749,164
764,160
717,012
677,429
608,241
620,708
730,259
550,626
697,099
Jul
839,963
942,291
837,782
864,942
821,529
795,689
702,885
817,659
918,193
667,473
820,841
Aug
843,526
915,970
867,167
809,261
901,428
733,704
743,622
809,917
800,385
700,219
812,520
Sep
783,501
806,129
713,434
743,967
723,147
707,003
582,266
687,267
612,173
652,724
701,161
Oct
Nov
Dec
664,659
572,366
558,414
668,855
568,995
543,961
642,178
588,165
548,999
690,112
597,691
563,405
651,225
551,030
512,911
586,497
523,105
519,221
550,367
456,714
466,332
552,277
461,512
452,802
511,918
430,083
413,661
488,186
422,888
432,809
600,627
517,255
501,252
Total
8,033,528
8,039,632
7,731,081
7,948,590
7,795,174
7,375,740
6,632,681
6,777,267
6,671,288
6,044,617
7,304,960
Yellow indicates highest month in 10-year period. Green indicates lowest month in 10-year period.
Graphs 6-3 takes totalized raw and finished water flows from 1997 through 2013 and presents the data as daily
average flow. Water production generally decreased over the last fifteen years. Again, the Utility distribution
system grew and service connections increased, but water production declined, mostly due to lost industrial
customers, and to an ever-increasing extent, the use of water conserving appliances, toilets, and shower heads.
Average daily raw water and finished water production in 2013 decreased from the previous year, falling over 1.1
and 1.0 million gallons per day respectively from 2012. Normal higher summertime demands did not occur in 2013
until late in the season (September) due to higher precipitation from spring through early August. These conditions
significantly reduced water usage for lawns and gardens.
Graph 6-3
The previous graph indicates that not all water pumped from Lake Michigan goes into the distribution system. Part
of the treated water is needed to run equipment and used for filter backwashing. Graph 6-4 exhibits the average
daily volumes of water needed just for conventional filter backwashing. In 2013, the average daily backwash water
increased slightly to 201,000 gallons/day. The coagulant change from ferric sulfate to poly-aluminum chloride
resulted in increased length of filter runs and lowered the number of backwashes accounting for the significant
reduced volumes compared to 2008 and before.
[33]
Graph 6-4
Table 6-3 presents the historical maximum and minimum day finished water flows to the distribution system since
1985. Recorded daily high flows for each year are highly dependent on weather conditions. In 1988, the RWU set
its all-time daily maximum flow. That year, the area experienced extreme drought conditions. December 31, 2012
set the minimum day finished water production mark over the last 28 years.
Table 6-3
Year
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
Maximum Day & Flow
Date
M.G.D.
24-Jul
33.726
23-Jul
30.884
17-Jul
39.792
21-Jun
45.381
7-Jul
37.169
16-Aug
39.456
16-Jul
43.359
11-Jun
39.072
27-Aug
38.926
16-Jun
41.938
13-Jul
40.353
5-Sep
33.389
16-Jul
36.619
14-Jul
36.476
14-Jul
39.121
31-Aug
34.324
13-Jul
36.379
16-Jul
35.261
18-Aug
37.796
2-Aug
32.854
16-Jul
36.476
17-Jul
33.305
1-Aug
33.640
1-Aug
34.445
28-Jul
30.918
30-Aug
27.999
21-Jul
32.149
12-Jul
35.045
10-Sep
30.380
Year
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
[34]
Minimum Day & Flow
Date
M.G.D.
1-Jan
13.606
26-Dec
13.411
26-Dec
13.719
1-Jan
14.642
1-Jan
15.086
25-Dec
15.604
29-Dec
15.506
1-Jan
14.436
26-Nov
15.931
25-Dec
14.097
25-Dec
16.565
29-Nov
13.964
25-Dec
13.455
26-Dec
16.051
26-Dec
15.293
1-Jan
14.545
25-Dec
15.104
28-Dec
15.607
26-Nov
14.375
25-Dec
13.438
1-Jan
12.847
23-Dec
12.897
25-Dec
14.576
19-Dec
12.831
28-Nov
12.533
20-Mar
12.405
31-Dec
12.470
31-Dec
11.132
10-Mar
12.144
Wholesale Customer Water Demand and Revenue
Graph 6-5 shows the historical trends of totalized water usage by the wholesale customers. Total finished water
production decreased significantly in 2013, as did water purchased by the Utility’s wholesale customers. The RWU
wholesale customers currently are the Village of Caledonia and the Village of Wind Point which purchases water
through the Village of Caledonia.
Graph 6-5
As seen in Graph 6-6, the actual revenues to the RWU from the wholesale customers generally increased
historically. This increasing trend is influenced most by rate increases. Graphs 6-5 and 6-6 show steep declines in
2007, resulting from the Village of Sturtevant changing from a wholesale to a retail customer. With the rate increase
enacted in 2011 and an increase in sales of purchased water, wholesale revenues rose again until 2013. Last year the
wholesale revenue declined by approximately $250,000, again the result of lower demands throughout 2013.
Graph 6-6
Residential Trend in Water Consumption
The RWU compiles many statistics for the Wisconsin Public Service Commission (PSC) on an annual basis. The
Great Lakes Compact stresses and urges water efficiency and conservation in the State of Wisconsin to preserve the
valuable resource of water that we have at our doorstep in Racine. The State has appointed a Water Conservation
position to oversee and monitor water conservation efforts in Wisconsin. Environmental groups have intervened in
water rate cases in a number of Wisconsin utilities to strongly encourage conservation efforts among residential
customer classes. Incentives for water conservation have been to enact inclining block water rates to discourage
more than the average use by residential customer classes.
The City of Racine is a good example of trends in residential consumption considering that the community is fully
developed and it is rare for new home starts. The information presented in Graph 6-7 indicates that water
consumption in the residential class in Racine, Wisconsin dropped by 20.1% from 2002 to 2010, increased by 6.2%
through 2012, and then dropped 10.2% in 2013. The overall trend decrease can be explained by many factors; an
aging population where the number of individuals per household may have dropped, rate increases in recent years
have caused residents to conserve in order to keep water bills at a tolerable level, installation of water saving toilets
[35]
and shower heads, reduction in lawn watering with increasing water rates and wetter periods of climate, economic
downturn that may be increasing the number of vacant properties or empty dwellings. The bottom line is that,
overall, the Utility has seen a declining trend in residential consumption.
Graph 6-7
It would be onerous on residential ratepayers to further reduce their consumption by imposing inclining block rates
to further provide a disincentive to use water on a local level. Lake Michigan serves as tremendous source water
that has not deviated in level by more than a few feet in over 100 years of record. The resource is currently plentiful
and Racine is not in the same situation as a community that might be using groundwater as a source of its water.
Racine Water Utility Rates
1992 – 2013
Over the course of the past 22 years, the consumer’s cost of water rose from $0.61 to $2.12/100ccf. This parallels
inflation over the same time period and reflects the true cost of water and improvements undertaken at the Utility to
improve supply, treatment, and water quality. These trends follow state and national trends on increased water rates
due to less consumption. Graph 6-8 shows the actual cost of water to a residential user based on 100 cubic feet (748
gallons) of water purchased and how many delivered gallons a customer receives per 1 cent. No water rate increases
occurred since 2011.
Graph 6-8
[36]
Section 7
Water
Treatment
Chemicals
Information
[37]
2013 Water Treatment Chemical Costs & Usage
Chemical costs comprise a significant portion of the annual operation and maintenance budget. The extent of water
production, quality of source water, and market variables influence the annual costs for chemical treatment. Chart
7-1 shows the 2013 chemical costs per chemical. Less water was treated in 2013, bringing the total chemicals costs
lower than 2012. The Utility uses six different chemicals for the direct production of water. For membrane cleaning
and neutralization, four chemicals are used. Graph 7-1 depicts the steeper incline in chemical costs from 2006
through 2009. Some of this is due to the inclusion of the membrane cleaning chemicals, but most is attributed to the
higher costs of chemicals. In 2013, the Utility spent $351,736 on treatment chemicals, $90,264 under the 2013
budgeted amount of $442,000.
Chart 7-1
Graph 7-1
Recent Historical Water Treatment Chemical Use
The RWU employs six chemicals to produce potable water to meet all Federal and State guidelines for water quality.
Without chemical addition, micro-organisms may survive in, particles would pass through to, and taste and odors
would exist in the finished product the Utility’s customers consume. The following figures summarize chemical
usage since 2002. Four other bulk chemicals are purchased and used in the membrane plant to maintain production
goals and for neutralization enabling discharge to the sanitary sewer system. .
Graph 7-2
Chlorine
Chlorine is a strong oxidizer used to disinfect the
source water to produce water free of viruses,
bacteria, and protozoa.
Chlorine dosages
remained relatively steady with the total pounds
fed decreasing over time due to lowered water
production. Total chlorine use decreased in 2013
due to lower water production.
Chlorine
treatment remains the single most important
chemical process in use at RWU.
Graph 7-3
Coagulant
A coagulant clarifies the water by producing a
small precipitate which settles to the bottom of a
tank. Since 2000, the RWU employed either
ferric sulfate or poly-aluminum chloride. Total
pounds fed have essentially remained the same
until 2012, with a significant decrease
experienced due to less water processed and
higher quality from Lake Michigan.
[38]
Graph 7-4
Potassium Permanganate
Potassium permanganate, another strong oxidizer,
serves numerous purposes at the RWU. The
Utility first used this chemical in 1967 for taste
and odor control. In 1995, chemical addition was
moved to the intake cones for zebra (& quagga)
mussel control. Permanganate gives the Utility
an early warning of water quality changes in the
Lake. The average dosage increased slightly in
2013.
Graph 7-5
Cationic Polymer
Cationic polymer (or coagulant aid polymer)
enhances the clarification of the source water.
This chemical contains positive charges along the
length of the molecule which attract the negatively
charged colloidal material found in Lake Michigan
water.
This chemical’s use has decreased
historically due to better mixing, lowered water
production, and optimization of pretreatment
operations.
Graph 7-6
Hydrofluorosilicic Acid (Fluoride)
The RWU feeds fluoride to be incorporated into
the tooth enamel and bone structure of children
and adolescents. The feed rate was dropped in
2011 to maintain a fluoride dosage of 0.7 parts per
million (optimum concentration to prevent dental
caries). Total annual pounds fed vary with the
amount of water produced.
Lower water
production equates to less chemical consumed.
Graph 7-7
Blended Phosphates
Since 1993, the RWU has fed a phosphate to the
finished water to decrease corrosion of metal pipes
in the distribution system and the customers
plumbing. The main purpose is to lower lead and
copper concentration in the customers’ “first draw”
water. In 2004, the Utility exceeded the lead
maximum contaminant level. Increases in amount
of phosphate fed since 2004 are due to the Utility’s
efforts to regain and maintain compliance with the
Lead & Copper Rule.
Membrane Chemicals
Citric Acid:
Used for acids cleans of membrane fibers to remove
inorganic foulants.
Sodium Hypochlorite:
Used for chlorine cleans of membrane fibers to
remove organic foulants.
Sodium Hydroxide:
Used to neutralize acidic cleaning solutions before
discharge to sanitary sewers.
Sodium Bisulfite:
Used for quenching chlorinated cleaning solutions
before discharge to sanitary sewers.
[39]
Section 8
Racine
Water Utility
Finished
Water Quality
[40]
2013 Racine Water Utility Finished Water Quality Report
Introduction
People using Lake Michigan as their source water are fortunate to have such a plentiful and high quality supply. A
properly operated and maintained treatment plant produces drinking water which is completely safe and pleasing to
drink. State and federal regulations require the RWU, and all water utilities, to monitor the treatment plant finished
and distribution waters. This monitoring ensures the highest possible quality and protects the public's health. Many
different parameters are tested at various frequencies. The attached water quality analysis lists all the chemical,
microbiological, radiological, and physical tests performed, their results, and the maximum contaminant levels
(MCL) allowed for each. Frequency of testing depends on each particular parameter and their chance of occurrence
and historical levels found. Typically, MCLs have not been established for some parameters due to incomplete
research, unknown occurrence data, or no known adverse effects. The Water Quality Analysis is divided into seven
sections. The first five deal with the required monitoring parameters and the last two with general information. The
Utility produces finished water meeting all state and federal regulations.
Inorganic Chemicals
The inorganic chemical section is subdivided into the primary, secondary, and unregulated chemicals. MCLs for the
primary regulated chemicals are based on the possible adverse health effects. MCLs for the secondary regulated
chemicals are based on the possible aesthetic influences on water quality. “Less than” signs before numerical results
indicate the contaminant is absent or the concentration is below the analytical detection limit.
Turbidity
Turbidity is a measure of water clarity and a very important monitoring parameter. Strict internal standards are set.
Turbidity measures the effectiveness of total treatment plant performance. Low turbidity indicates optimized
chemical treatment and filtration. High turbidity is aesthetically unappealing and allows pathogens to possibly
escape the disinfection process.
Organic Chemicals
Regulations established maximum contaminant levels for organic chemical based on their carcinogenic effects in
laboratory animal studies, with the results extrapolated to human exposure. This section is subdivided into volatile
organic chemicals (VOC), synthetic organic chemicals (SOC), and disinfection by-products (DBP). VOCs and
SOCs found in the water result from pollution in the watershed. DBPs result from naturally occurring organics
reacting with chlorine used for disinfection. “Less than” signs before numerical results indicate the contaminant is
absent or the concentration is below the analytical detection limit.
Radioactivity
In general, Lake Michigan contains very low levels or no radioactive isotopes. There is either no risk or extremely
little risk from radioactivity using surface water.
Microbiological Parameters
The most important process at any water treatment facility is disinfection. To ensure the water is pathogen free,
bacteriological tests are run daily on plant process and distribution waters. Treatment techniques require specified
minimum levels of treatment to remove or inactivate protozoa, bacteria, and viruses from the water.
The last two sections are for general information and are self-explanatory.
definitions footnoted in the text of the report.
At the end of the report is a list of
In summary, the RWU’s finished water is of excellent quality, meeting all state and federal limitations and
regulations.
[41]
2013 Finished Water Analyses (typical)
Updated January 1, 2014
I.
Inorganic Chemicals
A. Primary Regulated Chemicals
Parameter
Antimony
Arsenic
Asbestos2
Barium
Beryllium
Cadmium
Chromium
Copper
Cyanide
Fluoride
Lead
Mercury
Nickel
Nitrite
Nitrate-Nitrite
Selenium
Silver
Thallium
Results
0.19
0.92
<0.20
20
<0.13
<0.10
<0.6
<20
0.031
0.72
<3
<0.07
1.1
<0.05
0.42
<2.0
<0.26
<0.10
ug/l1
ug/l
MFL
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
mg/l3
ug/l
ug/l
ug/l
mg/l
mg/l
ug/l
ug/l
ug/l
Maximum Contaminant Level
6
ug/l
10
ug/l
7 million fibers per liter
2000
ug/l
4
ug/l
5
ug/l
100
ug/l
1300
ug/l
200
ug/l
4
mg/l
15
ug/l
2
ug/l
100
ug/l
10
mg/l
10
mg/l
50
ug/l
50
ug/l
2
ug/l
Copper and Lead Sampled at Consumer’s Taps
Copper, 90%
Lead, 90%
0.29
7.5
mg/l
ug/l
1.3
15
mg/l
ug/l
B. Secondary Regulated Chemicals
Parameter
Aluminum
Chloride
Chlorine, total
Color
Hydrogen sulfide
Iron
Manganese
MBAS, foaming agent
pH
Sulfate
Total Residue
Zinc
Results
<0.025
19
1.09
<5
<0.01
<0.003
0.0018
<0.1
7.70
23
190
<5.0
mg/l
mg/l
mg/l
C.U.4
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
ug/l
0.05 - 0.2 mg/l
250
mg/l
4
mg/l
15
C.U.
not detectable
0.3
mg/l
0.05
mg/l
0.5
mg/l
<6.5, > 8.5
250
mg/l
500
mg/l
5000
ug/l
C. Unregulated Chemicals
Parameter
Alkalinity
Boron
Calcium
Hardness
Hexavalent Chromium
Magnesium
Molybdenum
Phosphate, ortho
Potassium
Silica
Results
104
59
34
140
0.22
12
0.84
0.69
1.6
1.9
mg/l
ug/l
mg/l
mg/l
ug/l
mg/l
ug/l
mg/l
mg/l
mg/l
[42]
No Level Established
Sodium
Total Organic Carbon
12
1.5
mg/l
mg/l
II. Turbidity
Yearly Peak Turbidity
Average Daily Peak Turbidity
0.043
0.023
NTU
NTU
The regulation governing turbidity is a two-tiered rule:
1. Turbidity must never exceed 1.0 NTU leaving the treatment plant.
2. 95% of monthly samples must be below 0.3 NTU.
If either of these limitations is exceeded, public notice is required and in the case of (1), a boil water notice is
required.
III.
Organic Chemicals
A. Volatile Organic Chemicals
Parameter
Vinyl Chloride
Benzene
Carbon Tetrachloride
1,2-dichloroethane
Trichloroethylene
1,4-dichlorobenzene
1,1-dichloroethylene
1,1,1-trichloroethane
cis-1,2-dichloroethylene
trans-1,2 dichloroethylene
dichloromethane
1,2-dichloropropane
Ethylbenzene
Chlorobenzene
1,2-dichlorobenzene
Styrene
1,2,4-trichlorobenzene
1,1,2-trichloroethane
Tetrachloroethylene
Toluene
xylenes
Bromobenzene
Bromomethane
Chloroethane
Chloromethane
O-Chlorotoluene
P-Chlorotoluene
Dibromomethane
1,3-Dichlorobenzene
1,1-Dichloroethane
1,3-Dichloropropane
2,2-Dichloropropane
1,1-Dichloropropene
1,3-Dichloropropene
Isopropyltoluene P
1,1,1,2-Tetrachloroethane
1,1,2,2-Tetrachloroethane
1,2,3-Trichloropropane
Results
<0.20
<0.16
<0.29
<0.16
<0.28
<0.37
<0.13
<0.23
<0.30
<0.30
<0.29
<0.32
<0.31
<0.32
<0.11
<0.14
<0.43
<0.16
<0.11
<0.26
<0.65
<0.25
<0.30
<1.6
<0.29
<0.19
<0.24
<0.37
<0.34
<0.23
<0.29
<0.31
<0.28
<0.47
<0.5
<0.34
<0.32
<0.36
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
[43]
2
ug/l
5
ug/l
5
ug/l
5
ug/l
5
ug/l
75
ug/l
7
ug/l
200
ug/l
70
ug/l
100
ug/l
5
ug/l
5
ug/l
700
ug/l
100
ug/l
600
ug/l
100
ug/l
70
ug/l
5
ug/l
5
ug/l
1000
ug/l
10000 ug/l
B. Synthetic Organic Chemicals
Parameter
Alachlor
Aldicarb
Aldicarb sulfoxide
Aldicarb sulfone
Atrazine
Benzo(a)pyrene
Carbofuran
Chlordane
Dalapon
Di(2-ethylhexl)adipate
Di(2-ethylhexyl)phthalate
Dibromochloropropane
Dinoseb
Dioxin
Diquat
2,4-D
Endothall
Endrin
Ethylene dibromide
Glyphosate
Heptachlor
Heptachlor epoxide
Hexachlorobenzene
Hexachlorocyclopentadiene
Lindane
Methoxychlor
Oxamyl
Picloram
Polychlorinatedbiphenyls
Pentachlorophenol
Simazine
Toxaphene
2,4,5-TP(Silvex)
Aldrin
Butachlor
Carbaryl
Chlordane alpha
Chlordane gamma
Dicamba
Dieldrin
Methomyl
Metolachlor
Metribuzin
Propachlor
Results
<0.03 ug/l
<0.35 ug/l
<0.32 ug/l
<0.34 ug/l
<0.06 ug/l
<0.02 ug/l
<0.38 ug/l
<0.03 ug/l
<0.7
ug/l
<0.6
ug/l
<0.6
ug/l
<0.1
ug/l
<0.14 ug/l
<5 x 10-9ug/l
<0.32 ug/l
<0.06 ug/l
<0.5
ug/l
<0.01 ug/l
<0.01 ug/l
<4.7
ug/l
<0.02 ug/l
<0.02 ug/l
<0.04 ug/l
<0.03 ug/l
<0.02 ug/l
<0.03 ug/l
<0.32 ug/l
<0.07 ug/l
<0.1
ug/l
<0.02 ug/l
<0.07 ug/l
<0.33 ug/l
<0.16 ug/l
<0.05 ug/l
<0.03 ug/l
<0.34 ug/l
<0.1
ug/l
<0.1
ug/l
<0.23 ug/l
<0.07 ug/l
<0.36 ug/l
<0.03 ug/l
<0.07 ug/l
<0.04 ug/l
2
ug/l
3
ug/l
4
ug/l
2
ug/l
3
ug/l
0.2
ug/l
40
ug/l
2
ug/l
200
ug/l
400
ug/l
6
ug/l
0.2
ug/l
7
ug/l
3 x 10-8 ug/l
20
ug/l
70
ug/l
100
ug/l
2
ug/l
0.05
ug/l
700
ug/l
0.4
ug/l
0.2
ug/l
1
ug/l
50
ug/l
0.2
ug/l
40
ug/l
200
ug/l
500
ug/l
0.5
ug/l
1
ug/l
4
ug/l
3
ug/l
50
ug/l
Results
13.0
9.9
5.2
0.44
28.5
Maximum Contaminant Level*
------------80 ug/l
C. Disinfection By-products
Parameter (THM)
Chloroform
Bromodichloromethane
Chlorodibromomethane
Bromoform
Total
ug/l
ug/l
ug/l
ug/l
ug/l
[44]
Parameter (HAA)
Dibromoacetic Acid
Dichloroacetic Acid
Monobromoacetic Acid
Monochloroacetic Acid
Trichloroacetic Acid
Total
Results
1.5
8.2
0.3
0.7
5.0
15.7
---------------60 ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
ug/l
*No individual MCLs are established. All four THM concentrations summed must be below 80 parts per
billion and for all five HAA concentrations must be below 60 parts per billion.
IV. Radioactivity Parameters
Parameter
Gross Alpha
Gross Beta
Radium-226
Radium-228
Radon
Uranium, Total
Tritium
Strontium-90
Results
1.0 +/- 0.5
2.2 +/- 0.9
0.13 +/-0.05
0.6 +/- 0.5
14 +/- 8
0.9 +/- 0.2
20 +/- 150
.0 +/- 0.3
pCi/L
pCi/L
pCi/L
pCi/L
pCi/L
pCi/L
pCi/L
pCi/L
15
pCi/L
50
pCi/L
5
pCi/L
5
pCi/L
20000 pCi/L
8.0
pCi/L
V. Microbiological Parameters
Parameter
Coliform bacteria, total
Coliform bacteria, fecal
Heterotrophic bacteria
Viruses*
Giardia*
Cryptosporidium*
Results
0 per 100 milliliters
0 - 10 per milliliter
Treatment Technique
Treatment Technique
500 per milliliter
Absent
Absent
*Occurrence, treatability, and infectious dosage studies for Cryptosporidium are ongoing. Pending these
results, maximum contaminant level and treatment techniques will be established. Currently, testing
procedures for viruses, giardia, and cryptosporidium are unreliable and lengthy. In lieu of better analyses,
regulations require water plants to meet certain treatability standards to insure the drinking water is free of
these pathogens. The RWU meets these requirements.
VI. Temperature
2013 Annual Average
2013 Annual Maximum
2013 Annual Minimum
46.3 F
69.4 F
32.8 F
Water temperature is dependent on air temperature, amount of sunlight, and wind direction.
[45]
VII. Treatment Chemicals 7
Table 8-1 lists the chemicals used, their annual average dosages, and the purpose of their use in the
production of potable drinking water. Chemical application quantities can vary according to source.
Table 8-1
Chemical Name
Dosage Rate in ppm8
Primary Use in Treatment
Potassium Permanganate
0.18
Taste & Odor Control, Zebra
Mussel Control
Chlorine
2.07
Disinfection
Poly Aluminum Chloride
8.04
Particle Removal (Clarification)
Coagulant Aid Polymer
0.25
Clarification Aid
Fluoride
0.56
Prevention of Dental Caries
Polyphosphate
0.92
Definitions
1
ug/l stands for micrograms per liter or parts per billion.
2
Asbestos monitoring is now on a rotational schedule.
3
mg/l stands for milligrams per liter or parts per million.
4
C.U. stands for Color Units.
5
NTU stands for nephlometric turbidity units which is a measure of water clarity.
6
pCi/L stands for picco Curies per liter, a measure of radioactivity.
7
Chemical usage information is based on 2012 data.
8
ppm stands for parts per million.
[46]
Prevention of Piping Corrosion
Racine Waterworks Recent Historical Water Quality
Introduction
All public water systems must meet minimum Federal and State quality requirements for producing potable water.
The Utility tests for numerous parameters to gauge the water quality, the effectiveness of treatment, and to insure
public health. The frequency of testing of these parameters depends on past occurrence and the importance to public
health.
Turbidity
Turbidity measurement determines the degree of the water clarity. Turbidity’s importance is based on two
standpoints. First, from an aesthetic standpoint, crystal clear water is more desirable and palatable to the consumer.
Second, and more importantly, particles left in the water may provide hiding places for pathogens to escape
disinfection. So, the goal of any water producer is to provide water with the lowest turbidity possible.
Governmental maximum contaminant levels require the finished water discharged from the treatment plant to be less
than 0.30 NTU 95% of the time and never to exceed 0.50 NTU. Graph 8-1 shows the historical peak finished water
turbidity from 1997 through 2013. The slight finished water turbidity increases in 2008–2009 are due to the use of
different turbidimeters measuring the plant discharge. The dramatic lowering of finished water turbidity after 2005
is due to the addition of membrane filtration to the treatment process.
Graph 8-1
Membrane
filtration
begins in 2006
Disinfection
Disinfection of water remains the most important treatment process of any water supplier and is probably the most
important practice undertaken by society to protect public health. In underdeveloped regions of the world,
waterborne disease remains the number one killer of humans, even today. Graph 8-2 displays the historical free
chlorine residual in the finished water leaving the treatment plant. For many years, the RWU set free chlorine
residual goal at 1.0 parts per million. As seen in Graph 8-2, for most years, the Utility successfully maintained the
1.0 ppm goal. In 1997-1998, and again in 2004, the average finished water chlorine residual was significantly
higher. In these years, RWU staff operated with higher chlorine residual to meet disinfection regulations. In 1997
and 1998, the Utility constructed baffle walls in the east reservoir in order to bring the Utility in compliance with the
Surface Water Treatment Rule to provide the proper contact time for disinfection. With the east reservoir out of
service and new piping between the filter plant and high lift pump station under construction, the plant needed a
higher disinfection level to maintain the proper CT value due to the decreased contact time. In 2004, the Utility
again ran with a higher residual goal for a couple of months because of the removal of the east reservoir from
service for construction of pipeline to tie in the membrane filtration plant into the water treatment scheme. From
2005-2011, the RWU again returned to the 1.0 ppm goal. The slightly higher chlorine residuals in 2012 resulted
from a planned higher target level during the warmer months of the year to maintain proper amounts of chlorine in
the distribution system.
[47]
Graph 8-2
Water Stability
Alkalinity and pH measurement of the drinking water tell much about the effects of water treatment on the source
water and the corrosiveness of the water on plumbing and fixtures. Generally, higher pH and alkalinity make the
water less corrosive to metal piping. As seen in Graph 8-3, from 1997 through 2007, the pH of the finished water
sat around 7.4 standard units. In 2008, the average finished pH increased to 7.65 and has stabilized at approximately
7.70 through 2013. Finished alkalinity (Graph 8-4) from 1997 through 2005 decreased and stabilized through
2007. After 2007, the alkalinity concentration (parts per million) increased to 107 (2008), and 106 (2009-2011). The
decrease in alkalinity seen in 2012 and 2013 mirrored the lower raw water alkalinities. Both the pH and alkalinity
increase were caused by the switch to poly-aluminum chloride as the Utility’s coagulant. This chemical, when
dosed to the source water, lowers the pH less and depletes the alkalinity less than the iron salt coagulants the RWU
previously used prior to 2008. This significant improvement in water quality makes the water less corrosive and
provides a better foundation for building a protective film on pipe interiors.
Graph 8-3
Graph 8-4
Corrosion Control
The Lead and Copper Rule promulgated in 1986 required water purveyors serving over 50,000 people to conduct
corrosion control treatment. In 1993, the RWU began feeding ortho-poly phosphate blend to the finished water as it
left the treatment plant for corrosion control. Ortho-phosphate, over time, creates a thin protective barrier on the
inside of water pipes. This barrier ideally prevents direct contact between the water and the metal pipe. Thus, the
metal atoms cannot dissolve into the customer’s water. Graph 8-5 shows the ortho-phosphate concentration in the
finished water since 1997. From 1997 through 2005, the Utility maintained an ortho-phosphate concentration of
0.25 ppm. In 2004, the Utility exceeded the maximum contaminant level for lead.
In 2006, the Utility changed chemical suppliers and the blend of phosphate. For 2006-2007, the ortho-phosphate
residual target became 0.40 ppm. Beginning in late January 2009, the RWU increased ortho-phosphate
concentrations in the drinking water to a target of 0.70 parts per million (ppm) as it strives to lower corrosion rates
and reduce lead and copper concentrations in the consumer’s water.
[48]
Graph 8-5
Fluoridation
Fluoridation, practiced by the RWU since 1950, helps protect the population from dental caries (cavities). When the
fluoride level in drinking water is maintained at a concentration of 1.0 to 1.1 ppm, cavities are reduced
approximately 67% as shown by numerous epidemiological studies. Fluoridation, although not required under
Wisconsin State Statutes, is recommended by the American Water Works Association, the American Dental
Association, American Medical Association, and other public health agencies as a practical and economical way to
improve public health. In early 2011, the Center of Disease Control and Department of Health and Social Services
recommended a lower optimum dose for drinking water fluoride to be 0.70 ppm. Although not mandated, the RWU
voluntarily complied with this new guideline. Beginning in 2013, the optimum fluoride concentration for drinking
water of 0.70 ppm became mandatory by governmental regulations. Graph 8-6 shows the Utility’s historical
success at maintaining the fluoride residual at optimum levels.
Graph 8-6
[49]
Section 9
Training
&
Safety Programs
[50]
Professional, Technical, and Safety Training
In today’s highly technological, regulated, and legally influenced environment, continuing education and training
remains an extremely important component for conducting business. All employees of the RWU participate in
numerous mandatory safety training programs and diversity seminars. Supervisors are strongly encouraged to
participate in City-sponsored supervisory training to improve their management skills and extend their knowledge of
labor laws. Forty-two RWU employees possess either or both of the Wisconsin Department of Natural Resources
(WDNR) Surface Water and Distribution Operators licenses. Possessing a WDNR certified operator’s license
requires 18 hours of continuing education credits every 3 years.
Supervisory and Administrative Sessions
The Cities, Villages, and Municipal Insurance Corporation (CVMIC), one of the City of Racine’s insurance carriers,
provides numerous types of safety and administrative training seminars at no cost to their clients. The RWU utilized
many of these training opportunities in 2013. Table 9-1 summarizes the administrative training from CVMIC
received by Utility personnel this past year.
Training Description
Excavation/Competent Person
Coaching Employees
Confined Space for New Employees
New Supervisor Orientation
Employment Law
Interviewing
Hiring
Key Elements of Safety/Health in the Workplace
Employee Development Options for the Future
Discipline/Wrongful Termination
D.O.T. Compliance
Drug and Alcohol (CDL)
Harassment and Sexual Harassment
Table 9-1
No. of Employees
Attending
3
1
2
1
1
1
1
1
1
1
1
7
30
Session
Training Hours
7
16
8
8
16
8
8
6.5
6.5
8
16
1.5
1.5
Total RWU
Training Hours
21
16
16
8
16
8
8
6.5
6.5
8
16
10.5
45
Technical & Professional Sessions
Professional and technical training comprises another large portion of continuing education time. Maintaining staff
certification with the WDNR, keeping abreast of evolving technology, and knowledge of new State and Federal
regulations remain an essential part of Utility Staff’s training regimen. The RWU uses professional organization
such as the American Water Works Association, Wisconsin Water Association, the West Shore Water Producers
Association, etc., and vocational schools’ resources in meeting the continuing education requirements. Most
sessions presented by these organizations are fee based and the Utility budgets money each year for attendance to
these seminars. Utility suppliers (chemical and equipment) provide another source of education. Alexander
Chemical provides annual training to Utility operators and maintenance staff dealing with the technical and safety
aspects for correct chlorine gas application. Equipment suppliers periodically provide training on pumps, electrical
switchgear, etc. Fortunately, these valuable resources most often come at no cost to the RWU. Table 9-2
summarizes the professional and technical training taken in 2013.
AWWA Webinar - Leak Detection
Webinar – Operating Meter Reading
WWA Operations Seminar
WSWPA Spring Meeting
WWA Water Regulatory Affairs
WWA State Conference
AWWA National Conference
WSWPA Fall Meeting
WWA CLEAR Spring Session
WWA Emerging Issues
Alexander Chlorine Handling
Table 9-2
No. of Employees
Attending
11
12
2
2
2
2
1
1
5
1
8
[51]
Session
Training Hours
1.5
1.5
5
3
5
16,11
18
3
3
5.5
4
Total RWU
Training Hours
16.5
18
10
6
10
27
18
3
15
5.5
32
Diggers Hotline Seminar
Backflow Recertification
MPTC Surface Water
MPTC Distribution
WWA Customer Service
WRWA Cross Connection
WRWA Backflow Recertification
AWWA Webinar Hypo Generation
Nelson Electric Power Quality
Allen Bradley VFD
Johnson Controls HVAC
Busch Precision-Machine Failure
Lesman-Analytical Measurements
Lead Free Compliance
Engineering Ethics
Leak Detection Methods
Professional Sessions-Chief of Ops
No. of Employees
Attending
4
3
1
1
2
2
3
14
1
2
1
2
2
5
3
6
1
Session
Training Hours
3
3.5
24
16
7
8
8
1.5
6
16
40
6
7.5
6
2
2
54
Total RWU
Training Hours
12
10.5
24
16
14
16
24
21
6
32
40
12
15
30
6
12
54
Safety Programs and Training
One goal of any employer is to provide safe work conditions for its employees. Safe work conditions include proper
design and maintenance of facilities, use of approved equipment, and proper use of personal protective equipment.
Safety training forms the foundation to protect the Utility workers, describing practices workers can and must take
for self-protection. The safety policies and associated training are required under State (Wisconsin Department of
Safety and Professional Services) and Federal (Occupational Safety and Health Administration) regulations.
Following is the list of required safety training programs employees for the Utility and the City must take at
prescribed intervals.
Training Program Title
Program Description/Purpose
Asbestos Awareness……………………… Education regarding health effects of asbestos exposure and reduction
Blood Borne Pathogen…………………… Reducing exposure to blood borne and bodily fluid carried diseases
Chemical Hygiene Plan………………….. Assessment of health risks to personnel working in a laboratory setting
Confined Space Entry……………………. The definition of and proper procedures and safety guidelines for entry into
confined spaces
CPR/AED………………………………… Technique for performing cardio-pulmonary resuscitation and use of an
automated external defibrillator
Drug & Alcohol………………………….. Education regarding drug and alcohol abuse and effects on the workplace
Excavation/Trenching ………………….... Safe work practices to be used when excavating
Fall Protection……………………………
Use of proper equipment and PPE to protect workers when elevated above
work surface
Fire Extinguisher…………………………
Provides proper technique for fire extinguisher use and information on fires
Family Medical Leave Act………………. Educate employees and employers for proper use of and documentation for
workers to use family medical leave
Harassment/Sexual Harassment………….
Provide information to eliminate or limit unacceptable employee behavior
Hazard Communication………………….
Present information to employees on chemicals found in the workplace and
how to use material safety data sheets
Lockout/Tag-out…………………………. Education and procedures to de-energize equipment before performing
maintenance or work on the equipment or involved process
Powered Industrial Truck………………… Provide education and certification to employees who use fork lift trucks
Personal Protection………………………
Equipment (PPE)
Assessment of work duties to determine hazards for utilizing proper personal
protective equipment along with training for proper use of PPE
Respiratory Protection…………………… Medical evaluation of employees to determine ability to use respirators,
education on respirator use, and fit testing to ensure proper seals of equipment to
employee head and face
Safe Lifting………………………………. Give employee training on lifting techniques to avoid back and joint injury
[52]
Workplace Violence……………………… Provide training to workers and supervisors on methods to handle workplace
violence and threats
Work Zone………………………………… Training for workers regarding safe practices such as proper barricading and
signage when working in the public right-of-way
Table 9-3 provides the data for the safety training RWU employees took in 2013.
Hazardous Communication
Confined Space
Audio Metric Testing
Blood Borne Pathogen
Hearing Conservation
Powered Industrial Truck
Excavation & Trenching
Personal Protection Equipment
Lockout/Tagout
Fire Extinguisher
Work Zone Safety
CPR/AED
Table 9-3
No. of Employees
Attending
49
5
38
50
49
8
4
9
49
28
27
43
Session
Training Hours
1
4
0.5
1
1
4
4
0.5
1.0
2
2
1.5
Total RWU
Training Hours
49
20
19
50
49
32
16
4.5
49
56
54
64.5
Summing all the training hours which occurred in 2013, the total amount of training hours for the RWU personnel
was 1,130 hours.
Another facet of workplace safety is a safety committee. A very active safety committee exists at the RWU. The
RWU Safety Committee meets on a monthly basis (3 rd Tuesday). The Committee is made up of management and
union personnel from Engineering, Laboratory, Meter, Construction, Operations, and Maintenance Departments.
The Administration is represented by the Racine Water and Wastewater Utilities Chief of Operations. The Safety
Committee performs many functions. It reviews and amends all the above mentioned safety program policies.
Annually, it conducts safety inspections of the Hubbard Street facilities, the 7 elevated storage tanks’ buildings and
grounds, and the 4 booster pump stations. The Safety Committee encourages, accepts, and reviews safety
suggestions from all employees. The Committee recommends remedial actions to address the safety suggestion or
refers to management with recommendations if monetary outlays are required. The Committee reviews all reportable
accidents, assesses the cause, and may provide procedures and actions to prevent similar future accidents.
Reportable and Lost Time Accidents
As required by the RWU insurance carrier, due to worker compensation laws, the Utility maintains records on all
reportable accidents in the workplace. The RWU policy requires employees report any accident to their supervisors
which causes bodily injury, no matter the severity. These records are kept in the confidential medical files and
reported to CVMIC. Lower injury rates and decreased loss time due to injuries suffered in the workplace lowers the
insurance premium paid by the Utility. The list below summarizes all the reported workplace accidents which
occurred in 2013. The Utility incurred no lost time as a result of the accidents listed below.
Construction Department
January 1, 2013
February 15, 2013
Worker hurt left hand and wrist hurt by falling into a hole between shoring box and side of excavation. No lost work time.
Piece of rusty metal broke off equipment of drill rig during cleaning. Debris entered eye via the side of the employee’s
safety glasses. No lost work time
Meter Department
March 7, 2013
Meter reader slipped on an icy sidewalk spraining right ankle. Employee took sick time for recovery.
An employee who suffered an accident in 2012, but suffered no lost work time during that calendar year, did lose 123 hours in lost time due to
surgery to correct the injury suffered at work.
For 2013, the RWU recorded 0 hours of lost work time due to employee on-the-job injuries as defined and reported
on the OSHA 300 Log Form.
[53]
Section 10
Departments
[54]
Operations Department
The Operations Department consists of 11 individuals whose duties can be divided into three distinct sections of job
responsibilities:
Operations:
Technology:
Laboratory:
Consists of Operations Supervisor and 7 Treatment Plant/Pump Station Operators
Consists of Technology Supervisor
Consists of a Water Resource Chemist and Laboratory Technologist
Operations
This department’s responsibilities include all chemical water treatment, water filtration, raw and finished water
pumping, booster station pumping operations, and elevated water storage control. Treatment plant operators
perform routine laboratory tests daily to monitor water quality and provide information to make chemical dosage
decisions. Other significant duties include performing membrane fiber repair (1,595 in 2013), and generator testing
(7 test runs for 21 hours in 2013). Operators are responsible for receiving and proper off-loading all chemical
deliveries. Operators also perform custodial duties and small maintenance procedures. An operator is on duty for
work 24 hours a day, every day of the year.
Technology
This department oversees, modifies, and upgrades the software to run the Supervisor Control and Data Acquisition
system (SCADA), which Operations uses to monitor and alter plant performance, including all programmable logic
controllers. Other job functions include overseeing the radio communications system, the security surveillance
system, historical data servers, email systems, and attending to personal computer issues. The Wastewater Utility
also shares in available labor hours with this position.
Laboratory
The RWU Laboratory and its two fulltime employees perform daily routine monitoring of lake, process, finished,
and distribution waters. Additionally, water plant operators perform scheduled daily tests. The Utility Laboratory
serves four primary purposes: 1) analyzing the water to ensure it is free of harmful pathogens, 2) monitoring water
quality to ensure compliance with all federal and state water quality regulations, 3) testing of certain parameters to
supply an aesthetically pleasing product, and 4) monitoring all treatment processes to produce peak operating
efficiency.
Laboratory Testing
Chart 10-1 categorizes the microbiological sampling completed in 2013. Staff took over a total of 4,700
bacteriological samples and the laboratory personnel performed nearly 10,400 bacteriological analyses.
Chart 10-1
[55]
Chart 10-2 delineates the number of chemical and physical tests performed by laboratory staff, operators, meter
inspectors, and contractual laboratories. These entities conducted over 39,300 separate chemical and physical tests
in 2013.
Chart 10-2
- Chlorine testing includes treatment plant, routine distribution, construction, and special samples
- Majority of turbidity results from plant sampling
- Organic testing includes the following parameters: total organic carbon, UV254, and tannic acids
- Inorganic testing includes the following parameters: pH, alkalinity, potassium permanganate residual,
iron, ortho-phosphate, aluminum, fluoride, sodium, nitrate/nitrite, molybdenum, chloride, sulfate, boron
calcium, magnesium, manganese, potassium, silica/silicate, silver, and zinc
[56]
Maintenance Department
Ten fulltime positions staff the Maintenance Department. The positions include the Maintenance Supervisor,
Electrician, Mechanic I (2), and Mechanic III (6). This department performs, or is responsible for, all work
activities involving repair, upkeep, and preventative maintenance of buildings and equipment. Additionally, the
supervisor of this department coordinates and manages most work performed at the RWU facilities by contractors,
vendors, and service people. This department also maintains all facilities’ grounds such as grass mowing, shrub
trimming, and snow removal. Facilities include the main campus at Hubbard Street (Pump Station, Filter Plant,
Service Building, Generator Station, and Membrane Filter Building), 4 booster pump stations (Perry Ave., Newman
Rd., Hwy. 20, and Rayne Rd.), 6 elevated storage tanks (Summit Ave., Coolidge Ave., Regency Mall, Perry Ave.,
Newman Rd., Renaissance, and Broadway), pipe storage yard at the Regency Mall tank grounds, and a storage
garage on Michigan Avenue in Sturtevant.
2013 Completed O & M Projects
Table 10-1
Project #
Project Name
Project Description
1
Boiler Ignition
2
Compressor Replacement
Modify to LP ignition on main filter plant boiler to accommodate for fuel oil operation
Replace air conditioner compressor for membrane plant electrical room
3
Concrete Sealing
4
Battery Replacement
Repair backwash drain channel leak on filter bed #13
5
Newman Road BPS Pump #2
6
Heater Replacement
7
Air Dryers
8
Service Building Remodeling
9
Hwy 20 BPS Pressure Tank
Replaced air bladder in Highway 20 Booster Pump Station pressure tank
10
Circuit Board
Replaced malfunctioning circuit control board in low lift pump #2 VFD
Replace all batteries in filter plant Uninterruptible Power Supply
Repaired and modified booster pump 2 water seals
Replace PAC tower heater
Replace 2 air dryers for membrane plant valve air system along with pipe modifications
11
LL Pump 3 Impellor
12
High Lift Pump 11 Cover
Installed new drop ceiling, painted, replace lighting in Service Building entryway
Removed, repaired, and installed low lift pump #3 impeller
Repaired leaking pump cover on high lift pump #11
2013 Capital Improvement Projects
Table 10-2
Project #
Project Name
Project Description
1
Boiler Replacement
2
Valve Automation
Planned for and coordinated removal of old boiler and installation of new boiler system in Service
Building
Installed motor actuator, power wiring, and control wiring for basin 3 decant valve
3
Lighting Upgrade
Continued replacement of sodium vapor and fluorescent lighting with light emitting diode fixtures
4
5
6
7
HVAC
Installed split system HVAC unit for backwash motor and VFD room
Vacuum System
Installed new vacuum compressor and air receiver tank for membrane plant permeate pump system
Backwash VFD
Department worked with contractor to install new motors, VFDs, and rehabilitate pumps
Doors
Replaced Service Building main entry door and roof access door
[57]
2013 Service Contracts
Table 10-3
Contract
#
Contractual Service
Name
1
Generator Maintenance
2
Generator Plant
Switchgear
3
Solids Dewatering
4
Elevator Maintenance
5
Elevated Storage Tanks
6
Intake Inspection
Contractual Service Description
FABCO annually performs Level 1 and 2 inspections, change antifreeze and batteries
Performed preventive maintenance w/Pro Power on generator switchgear
7
Fire Extinguisher
Synagro, Inc. conducted spring and autumn semi-annual on-site pumping, de-watering, and
landfilling of treatment residual solids
Otis Elevator conducts inspections, preventative maintenance, and repairs as required by code
Utility Services, Inc. conducted annual inspection of Perry Ave. and Mall tanks, performed
needed repairs, and scheduled painting of interior and exterior surfaces
Chase Diving Services conducted inspection on 3 intakes and shore shaft and re-bolted new
thrust restraint in 54” intake at entry into Shore Shaft A, cleaned out debris in inverts of 9 cones
134 Fire extinguishers serviced annually
8
Crane Inspections
Annual inspection of 10 cranes, 6 gantries, and 2 electric hoists
2013 Routine Annual Maintenance Tasks (not all inclusive)
Table 10-4
Task Name
Lubrication
(Oil Changes)
Task Frequency
19 Pump Motors
13 Pumps
16 Flocculator Drives
10 Air Compressors
Task Description
Routine oil changes completed based on hours of operation or time
Lubrication
(Greasing)
14 Pump Motors – Weekly
Provided grease to prevent wear on rotating equipment
Pump Packing
1 Low Lift Pump
3 High Lift Pumps
2 Small Wash Water Pumps
8 Flocculator Shafts
(Basins 4 & 5)
3 Booster Pumps (Perry)
Shafts are packed to prevent material loss and keep water leaking to a
minimum around rotating shafts on equipment
Fire Extinguisher
Inspection
134 Semi-annually
SCBA Flow Testing
Exit and Emergency Light
Inspection
Transmitter Calibration
Eye Wash Station
7 – Yearly
68 Exit Lights
51 Emergency Lights
67 Transmitters Yearly
10 – Semi-annually
Power Gate Maintenance
4 – Semi-annually
Boiler Service
Pit Pumping
2 – Daily (yearly)
Filter Change outs
140 – Hours of Operation
Exhaust Fan Inspection
Chemical Feed Hoses
Fork Lift Truck
10 Chemical Dosing Pumps
1 Vehicle
Inspect all fire extinguishers in buildings and vehicles, replace media at
expiration time
Test annually to insure working order
Test annually to insure proper working order
Calibrate transmitters to maintain proper flow and pressure reading
Change eye wash fluid and check operation of stations
Perform inspection, lubrication, and check stops of 3 motorized gate
openers
Perform chemical checks and other boiler maintenance
Pump out valve and electric pits in spring and autumn
Change filters on various pieces of equipment based on time interval
and/or hours of operation recommendations
Inspect and repair, if necessary
Replace chemical feed hoses on water treatment peristaltic pumps
Inspect and service the Utility fork lift truck
Other Maintenance Tasks






Buildings and Grounds Maintenance
Safety Policies and Procedures Development & Review
Performance and Maintenance of Safety Equipment
Continue to Upgrade Boiler System
Routine and Seasonal Custodial Duties (Floor waxing, snow removal, etc.)
Miscellaneous Equipment Maintenance (e.g. installation of chemical anti-siphon valves, replacement of
flocculator drive chain, thawing of level transmitter water line, etc.)
[58]
Meter Department
The Meter Department employs 11 people; the Meter Supervisor, Clerk/Dispatcher, Meter I (5), Meter II
(1), Meter IV (1), and Meter V (2) positions. The Meter Department hired 1 employee in early 2013 to
fill an open position due to retirement and subsequent job transfers. This Department’s responsibilities
include reading all meters in the retail system, reading meters measuring water sold to the wholesale
users, changing meters as per Wisconsin PSC rules, testing meters for accuracy, taking water quality
samples in the distribution system, tapping water mains for new service connections, handling incoming
phone calls, conducting locates of RWU underground facilities and responding to customer concerns.
In 2013, the Meter Department, with the assistance of a private contractor (Hydro Design, Inc.), continued
the Utility cross-connection control inspection program. This program, first implemented in 2011,
expanded the duties of this department significantly due to the time needed for inspections, public
education, and verification of corrective measures. Meter Department personnel conducted 2,405
residential inspections in conjunction with residential meter change outs and meter installations. Hydro
Designs conducted another 374 inspections focused on commercial, industrial, and municipal facilities.
At the end of 2013, the distribution system consisted of 34,217 services with 34,449 meters ranging in
size from 5/8” to 12” in diameter measuring volumes used by the Utility customers. The responsibility of
reading the vast majority of these meters falls to the Meter Readers, who, on a quarterly basis, walk or
drive the various routes, either manually or electronically recording the customers’ water usage.
Industrial meters are read and invoiced monthly in the same manner.
The Meter Inspectors take water distribution samples, perform water service taps, conduct inspections,
connect new customers, and provide customer service by answering questions and troubleshooting
problems that the customer may have with their water usage or water quality issue.
Meter Repair Workers perform the bulk of meter changes. Meters need to be replaced periodically per
requirements of the PSC. Large meter tests must also be conducted, some annually, and most meters
returned to the shop after removal are also tested in-house. The Meter Repair Workers also track
inventory of meter supplies in the stockroom and accommodate bulk water trucks that come to the plant
to be filled.
The Clerk/Dispatcher answers/routes phone calls, schedules appointments, and greets visitors who come
to the plant. This position is also responsible for the extensive record-keeping of meter department data.
In recent years, the RWU implemented use of automated meter reading (AMR) technology to supplement
the manual reads taken by the Meter Department. The RWU employs two versions of AMR, telephone
reading (Access PlusTM) and radio reading (OrionTM). These systems dramatically decrease time needed
to read residential areas and industrial/commercial customers. Using the Access Plus system, water
meters located in high water use facilities “call” in the meter readings to the Annex offices over phone
lines every month to bill the industrial customers. The monthly bill improves the Utility’s cash flow and
provides real time information to the Utility’s industrial customers on their water use. Over 56% of meter
reads are done through an automated process. At the end of 2012, the RWU decreased its number of
Access Plus meters from 14 (2012) to 2. These meters were replaced with the Orion system making
reading easier and more standardized. By the end of 2013, the RWU employed approximately 19,124
Orion meters in its distribution system. As a matter of policy and municipal codes, the RWU now installs
Orion type meters on all new customers services and replaces existing meters when meter change-outs are
scheduled. The use of this latest technology makes meter reading more efficient and more accurate.
[59]
Work Summary
Work Performed
Meter Changes
Orion Retrofits
Turn On/Sets/New Customers
Large Meter Tests
Meter Tests
Water Service Taps
Cross Connection Inspections
Underground Facility Locates
2006
705
1,131
316
7
886
28
No Formal
Program
Not
available
2007
1,753
357
364
30
884
37
No Formal
Program
Not
available
Table 10-5
2008
1,115
1,008
235
46
902
27
No Formal
Program
Not
available
2009
2,074
840
220
51
2,507
17
No Formal
Program
Not
available
2010
1,312
546
160
62
1,509
10
No Formal
Program
Not
available
2011
1,756
128
207
80
1,836
3
2012
2,045
216
233
43
2,349
6
2013
2,398
37
244
71
2,671
7
530
2,439
2,799
3,257
845
636
Looking at the above work summary, 2013 showed changes in the amount of work performed in certain categories
from the previous years.

Residential meter change-out and testing increased due to the hiring/training of 1 Meter I worker (filling
retirement vacancy in 2012) and the emphasis on this essential part of their jobs. Capital funding for meter and
Orion technology was set at $500,000 for 2013.

The Meter Department concentrated on large meter testing and replacement in 2013 with the number increasing
by 28 from 2012. Since the large meters in the system account for a large portion of consumption and revenue,
it is extremely important to maintain reading accuracy and ensure proper revenue to the Utility.

New customer meter sets again increased in 2013; many of these were foreclosure properties, although new
construction picked up as well. There were 7 new water service taps made for residential homes. For
properties where the meter needed to be reset (due to the activities of the winterization/property maintenance
companies), the Utility assessed approximately $5,500 in meter reset fees.

The staff again dedicated many labor-hours performing meter take-outs due to the high volume of vacant or
foreclosed properties. The cross connection control inspection program completed its first full year in 2012,
demonstrating excellent progress. Of the 2,799 cross connection inspections, 2,405 were residential and 374
were commercial/industrial/public authority.

Bulk water sales from tanker fills at the Service Building and distribution hydrant fill stations totaled $23,278 in
2013.

The Utility billed approximately $20,341 to customers for purchased meters or for damaged/broken equipment
(i.e. iced damaged meters), and reset fees. Increase over 2012 mainly due to vacant/foreclosed properties now
being sold and repair bills for damaged bulk water fill equipment.

Seasonal meters sets (partial-year customers) generated $102,945 for the RWU.

For 2013, Meter employees continued to separate metals from the old removed meters for recycling. Recycling
of meter scrap metal generated $10,046 for the Utility to supplement capital funds for meter purchasing.
The Meter Department remains an integral part in the operation and viability of the Racine Water & Wastewater
Utilities. It is often said that a meter department serves as the “cash register” to water department operations. Here
in Racine that is very true; and, in fact, meter equipment and reads taken by the meter department staff are also used
for the basis of billing charges for the RWU and several sewer districts in the outlying areas.
[60]
Construction Department
The Construction Department consists of eleven full time employees; the Construction Supervisor,
Construction I (3), Construction II (2), Construction III (2), Construction IV (2), and Construction V (1).
Two of the above Construction workers also serve in the capacity of Crew Leader. The Construction
Department works closely with the Engineering Department, and is overseen by the Chief Engineer.
The main duties of the Construction Department are to:
 Perform regular system maintenance
 Repair main breaks, and replace or repair broken valves, hydrants, and water services
 Thaw frozen water services
 Respond to service calls and Digger’s Hotline Locate requests
 Perform leak detection in the distribution system
Distribution System Maintenance & Repair
The distribution system averages over 100 water main breaks per year. Repairing these breaks consumes
a large portion of the Department’s time during the winter and summer months, when most main breaks
occur. As breaks lessen over the spring and fall months, the Department then focuses on maintenance and
upkeep of the distribution system.
To maintain the system and keep it in good working order, the Department must exercise valves, operate
hydrants, and adjust water services each year on a continual rotation. Maintenance of the distribution
system is logged via the GIS system, which makes for quick and easy reporting. The Department works
with city, county, and state paving contractors to ensure all valves and hydrants are in good working order
prior to the placement of new pavement.
Maintenance and repair work performed in 2013 included, but was not limited to, the following:
 97 Main breaks dug and repaired
 1,452 valves exercised
 37 Broken valves repaired or replaced
 9 New valves installed
 4,032 Hydrants exercised
 103 Hydrants flushed
 32 Broken hydrants repaired or replaced
 3 New hydrants installed
 168 Water services repaired
 10 Lead services replaced
 752 Hydrants painted
Valve Repair
Service Calls
The Construction Department responds to calls 24 hours a day, 365 days a year from residents, plumbers,
contractors, and other state and municipal entities.
For example, in 2013, the Construction Department performed 6,650 of the 8,270 Digger’s Hotline
Locate requests received by the Utility, many of them after regular working hours. The Department also
responded to a variety of other requests, including infrastructure adjustments for road building contractors
and water main connections for developers.
[61]
Engineering Department
The Engineering Department consists of six full time employees; the Chief Engineer, Civil Engineer II,
Engineering II Technicians (2), an Engineering Technician/Inspector, and an Engineering Aide II. The
Department also includes 2 part time construction inspectors who work seasonally.
Though the Engineering Department fills a lot of roles for the Racine Water Utility, its main duties are to:
 Design and manage water main replacement projects
 Replace lead services
 Respond to Digger’s Hotline locate requests
 Plan and coordinate work done by other public and private entities
 Provide technical assistance to other RWU departments
 Update and develop the Utility’s GIS system
Water Main Replacement Projects
To keep up with failing water mains that have reached the end of their useful life, the Engineering
Department designs and manages some 2-3 million dollars in capital improvement projects each year.
Main replacements are typically split between several contracts and spaced throughout the year. Spring
contracts focus on main replacements where road improvements are scheduled to be performed later that
year, and summer/fall contracts focus on replacing the most problematic mains in the system.
Whether or not a main needs replacement depends on several factors, including:
 Pipe age, diameter, and material
 Break frequency and recent recurrence level
 Condition of the street and timeline of potential street improvements
 Break severity and associated repair costs
 Impact to distribution system and customers
The Utility typically experiences over 100 water main breaks per year. Data on each break, such as the
pipe material type and cause of break, is recorded by the Engineering Department and then used to help
prioritize main replacements each year. The figure below shows historical yearly main break totals.
[62]
As the figure shows, the Utility experienced 97 water main breaks in 2013, a relatively average number.
The Utility began its yearly water main replacement capital improvement project in 1986, as indicated in
Figure 1. A water main break trend line is shown for those years prior to 1986 and a second trend line is
shown for years 1986 to present. Comparing these trend lines, the water main replacement program
appears to have reversed the trend of increasing water main breaks.
2013 water main breaks, summarized by month and break type, are show below.
The table below lists the contracts designed and managed by the Engineering Department in 2013, with
the majority of these contracts pertaining to water main replacement.
2013 Engineering Department Contracts
Project
W-13-1
W-13-2
W-13-3
W-13-4
Contractor
Earth X, LLC
AW Oakes & Son
AW Oakes & Son
RAZA of Racine
Description
Main Replacement
Main Replacement
Main Replacement
Pavement Replacement
Cost
$235,000
$372,000
$1,270,000
$264,200
Lead Service Replacement
As part of its capital improvement program, the Engineering Department replaces dozens of lead services
each year. Lead replacements are typically performed on water main replacement projects where the lead
service is replaced in conjunction with the installation of the new water pipe. In some instances, the old
[63]
lead service is replaced, but the old water pipe is left in place. This typically occurs when the old pipe is
still in good condition, but the old lead service is replaced in anticipation of a street reconstruction
project.
The Engineering Department replaced 117 lead services in 2013 through its CIP projects, a fairly typical
number.
Digger’s Hotline Locates
Like other utilities, the Water Utility must respond to Digger’s Hotline locate requests. Locating duties
are split between the Engineering, Meter, and Construction Departments. 8,270 locates were performed
by the Utility in 2013, with the Engineering Department performing 1,013 of the total.
Plan and Coordinate Work by Others
In addition to its own projects, the Engineering Department works closely to see that projects funded by
other public and private groups are properly and successfully completed. These types of projects include:
 Development of new subdivisions
 Development of commercial sites
 Road and highway improvements
 Utility construction
 Site remediation
When new mains are to be constructed by others, outside engineering groups first submit design plans to
the department for review and approval. Then, during construction, we help resolve any problems that
arise, and also ensure that any newly installed mains are properly pressure tested and safe water sampled.
Upon completion of the project, we verify that all newly installed infrastructure is in good working
condition and up to specification before accepting that infrastructure into our distribution system.
One major developer-funded project of note for 2013 was the CTH “H” water main extension project,
which was installed to ensure adequate water supply to a newly constructed warehouse near CTH “H” and
STH “11”. The water main extension provided for a 12” water main loop between the Utility’s Broadway
and Renaissance water tanks. This loop provides for better water pressure, flow, and fire protection for
the western portions of Sturtevant.
The table below lists the public water main extensions that were built by developers in 2013.
2013 Developer Funded Public Water Main Extensions
Project
CTH "H"
Primrose
Developer
Village of Sturtevant
Primrose Retirement
Description
New 12" main along CTH "H"
Public 8" main for new retirement community
Footage
2,740
1,850
Value
$300,950.00
$180,000.00
Technical Assistance
The Engineering Department works closely with other departments to provide technical assistance when
needed, including:
 Locating of hard to trace water mains
 Referencing and utilizing information found in our historical archives
 Tracking and logging of work done by field operations
 Investigating and troubleshooting discrepancies in the distribution system
 Creating reports, maps, graphics, and other displays
GIS System
The Utility’s GIS system is dynamic, ever-improving, and requires daily maintenance to keep its
information correct and up to date. The GIS system allows the user to view, graphically, all the
[64]
components of the Utility’s distribution system, including water mains, valves, water services, and
hydrants. The GIS hosts information such as the age of a piece of pipe, or whether a water service to a
customer’s home is lead or copper.
The GIS system is accessible via the internet, which allows any utility employee armed with a laptop
instant access to all the information they’ll need to perform a digger’s hotline locate or investigate a
problem.
Utility employees are also able to update the GIS system in the field, which allows them to log when a
particular valve is being operated, or why a particular hydrant is being flushed.
The Engineering Department is looking to upgrade the GIS system in 2014 by migrating to an ESRI
platform, which will make the GIS system much easier to use on mobile platforms.
GIS Web App
[65]
Appendices
[66]
Racine Waterworks Historical Milestones
1886
Initiation of construction of water intakes, distribution mains, and the Reichert court pumping
station.
1887
Lake Michigan water pumped into the distribution system via a 24-inch cast iron intake pipe
7,559 feet long.
1911
Hypochlorite of lime used for disinfection. Steam pump station was enlarged.
1919
The City of Racine completed purchase of the privately held Racine Water Company.
1922
Liquid Chlorine in cylinders used for disinfection.
1924
The first two coagulation and settling basins completed. The last death due to typhoid fever in
Racine recorded.
1927-1928
The 12 million gallon per day filtration plant completed.
1927-1929
Installed a new 36-inch cast iron intake pipe; 6,963 feet in length.
1930
Erected the 2.75 million gallon storage standpipe west of the city. Anhydrous ammonia first
used to neutralize industrial chemical taste and odor pollutants.
1933
The modern electrical pump station built at Hubbard Street and Michigan Boulevard.
1935
Powder-activated carbon first used for taste and odor control.
1936
The filtration plant enlarged to 20 million gallons per day capacity.
1939
The construction of a third settling basin and enlargement of the two original basins completed.
The Service Building construction completed. The river crossing tunnel at Main Street was
constructed.
1950
Sodium Silica-fluoride fed for first time for prevention of tooth decay.
1957-1958
The filtration plant enlarged to 40 million gallon per day capacity. Two new settling basins
added under the front lawn. Two 1.5 million gallon elevated storage tanks erected on the north
and south sides of the City. The 150,000 gallon elevated tank and 2 booster pumps installed at
Perry Avenue. 5-1/2 miles of 30” and 24” transmission mains installed.
1964
Lake Michigan at all-time recorded low level producing treatment problems.
1966
Dual media filtration began with introduction of anthracite “capped” filters.
1967
Potassium permanganate introduced for taste and odor control.
1970
Installed the 54-inch concrete pipe intake, 4,500 feet long terminating in 9 intake cones.
1975
Cationic organic polymer introduced to treatment regimen to enhance clarification.
1977
Filter backwash waters recycled through newly constructed retention basin eliminating discharge
to Lake Michigan.
1978
Basin treatment sediments pumped to sanitary sewers for wastewater plant treatment.
1979
New bank of electrical switchgear, 3 new transformers, one 25-mgd high lift, and one 25-mgd
low lift pump installed in the main pump station on Hubbard Street.
[67]
1980
2.3 miles of new 36-inch and 48-inch diameter water transmission mains placed in service.
Utility installed a 1,600 kilowatt diesel turbine electrical generator in the Hubbard Street pump
station.
1981
3.1 miles of new 30-inch and 24-inch diameter water mains placed in service to balance
distribution hydraulics. Booster pump station addition completed on west side. Two million
gallon elevated storage tank erected on southwest side of city.
1982
Eight original filters rehabilitated in the 1926 treatment plant.
1985
Chlorination treatment practice modified to reduce trihalomethane formation. Ferric chloride
used as the primary coagulant with polymer to reduce sludge, improve clarification, and reduce
costs.
1986
Lake Michigan recorded at an all-time high level.
1989
Zebra mussels discovered in intake system. First discovery of mussels in Wisconsin.
1991
Completion of new boiler house and control room. Backwash water piping replaced and
computerization of pumping station, treatment plant, and remote facilities completed.
1993
Phosphates first fed to finished water to prevent corrosion in distribution system.
1994
Racine Water Utility issues boil water notices on two consecutive weekends due to discharge of
“high” turbidity water into distribution system.
1995
Potassium permanganate feed lines extended to intake cones and conversion of emergency low
lift pump station to new chemical feed station completed.
1996-1997
Basins 1 and 2 demolished and rebuilt for pretreatment project. New chemical feed systems,
mixing chambers, and plate settlers installed to improve water pre-treatment and filtration.
1999
Perry Avenue Booster Pump Station capacity expanded with the replacement of booster pumps 1,
2, and 3 along with re-configuration of suction and discharge piping.
1997-2000
Reservoir and Baffling project construction completed. The east reservoir retrofitted with
concrete baffle walls to increase chlorine contact time and new piping installed from filter plant
to east reservoir and back to pump station to provide “true” flow through the finished water
system.
2000-2002
Low Lift project provided a firm source water pumping capacity of 60 mgd. Electric motors
relocated above grade to provide protection from potential flooding. Two pumps installed with
variable frequency drives for more flexible pumping operations.
2003
The Utility completed construction of the Standby Generator Station. This facility provides
emergency power to operate the entire Hubbard Street campus at peak operation conditions.
2004-2005
The new Membrane Plant provides ultra-filtration to remove all micro-organisms and
particulates in the finished water, producing water of the highest quality to meet current and
future regulations.
2005
Construction completed on the Highway 20 booster pump station. This station provides water to
the Highway 20 corridor out to Interstate 94.
2006
Construction completed on the Newman Road booster pump station and ground reservoir. This
facility provides redundancy to the high pressure zone and capacity as the water distribution
system expands.
[68]
2007
The Racine Water Utility purchases the former Sturtevant Water Utility including the distribution
system, Rayne Road booster pump station, Broadway elevated tank, and the Renaissance
elevated tank.
2008
Coagulant chemical, mechanical and operational changes made to reduce basin solids disposal
costs, decrease back-washing costs, and improve membrane plant performance.
2009
Phosphate inhibitor formulation changed to further lessen corrosion rates in the distribution
system and reduce first-draw water lead and copper concentrations.
2011
The Racine Waterworks marks its 125th year anniversary. The US Conference of Mayors names
the City of Racine the winner of “America’s Best Tasting Water”.
[69]
Racine Water Utility Flow Schematic
Intakes:
24”, 36”, 54”
Shore
Shaft
A
Low Lift
Suction
Well
Shore
Shaft
B
Backwash Recycle
Location @ 8’ Tunnel
Backwash Water
Retention Basin
(1977)
Backwash
Water Cistern
(1957)
To Sanitary Sewer
System (Alternate)
Membrane
Backwash
Recycled to
Shore Shaft
B
To Sanitary (Alt)
Backwash
Membrane
Plant
7 Trains
Decant used to empty
basins for solids removal
Convention Dual Media
Filter Beds (16)
Coagulation
Flocculation
& Sedimentation
Basins
(Backwash water flows by
gravity to either Cistern or
Retention basin, both tanks
hydraulically connected)
(Decant water flows to retention basin by
gravity. Decanting occurs semi-annually)
(Water flows from
clearwells by
gravity to
membrane plant)
CT Reservoir
High Lift Pump Station
[70]
[71]
[72]
[73]
[74]
[75]

2013 Racine Water Utility Annual Report

Transcription

Similar documents

Smart Energy Source - Oklahoma State University

Dean Logan`s Blog: Bobblehead Contest, The

Agenda Item Cover Sheet

GA Power Utility Easement Pebblebrook HS

Revenue Systems Brochure

PureNet™ Asset Management

Kulim 220MW CCGT

4929 139,000

We specialize in billing all utilities including electric

SC76 with 5 accessories v01.qxd