Blog 24 July
Blog 24 July
1. Intro
Apologies to all my avid fans for not blogging for a while, things have been getting pretty busy and thus interesting for me on site. I will try and keep this succinct, but also cover all the detail that will give you an idea of the site. I apologize for the length of this blog!
2. SSP Progress
The SSP is starting to move out of limbo, though we have yet to agree to the contractors proposal to the change order we sent (seeing as his quote was 4 times higher than our estimate). The commissioning agent has received their back-pay and so is now willing to come back to site, and continue the final stages.
2a. “Matched Flow” discussion.
I called a meeting to discuss the current issues with matching the 2 flows through the heat exchanger. This is heat exchanger is designed to transfer from one tank to another, whilst emptying and filling the tanks. As such having matched flow is essential to prevent either having to spend more time heating the filling tank or having to use copious fresh water to cool the discharge before it hits the sewer. This had been highlighted previously in the commissioning process and a change order agreed to correct it, however we have found that it is still not working as well as we would expect.
It is basically a controls problem, similar to the ones we discussed with Steve and the main problem is the speed with which it can reach its set point. This time was not originally specified, and so currently takes around 10 minutes to reach full flow. This is slowing the rest of the process to an unacceptable degree. It looks like we may have to issue an additional change order stating the time it should reach set-point in (ie full controlled flow)
The learning point: is that specification must truly reflect your expectations, especially on innovative plant equipment.
2b. Failed Cook test.
One of the cook tanks that is used to pressure cook the effluent appears to have failed its “Bio-Challenge” test. This is intended to simulate using the cooker to sterilize 8000 US Gal of effluent. It is conducted with temperature probes to monitor the temperature that the tank maintains, and also a set of small glass vials each of which has a biological sample which must be sterilized. The temperature did not stay above 250F for the full hour and the sample still had live spores. This is hopefully some form of failure in the testing rather than an equipment failure. More information will be coming soon which will allow me to analyze it properly.
Learning point: that commissioning and testing is best handled by a third party with no previous attachment to the contractor.
2c. Proposal from SSP
Having sent a Request for Proposal (RFP) from the contractor they have returned a quote 4 times higher than expected ($2M rather than $500K and 264 days rather than 60). I have been “getting into the weeds” of this proposal and found many laughable mistakes (or they may be attempted extension of reality, such as 25 hour working days). As I had stated in previous Blogs the contractor is way behind schedule and appears to be acting fairly irrationally, and trying to recoup some costs by blaming everything on the USACE as well as trying to charge huge fees for the slightest effort. They have also just replaced their onsite project manager, again a strange move when so close to completion, so we will have to educate the new project manager about the details of the project.
Learning point: that all submissions from a contractor must be fully scrutinized, as dependant on how honest they are they may try all manner of tricks.
2d. Schedule adjustments
We have also been looking into the schedule adjustments made to the SSP by the contractor. Again there are many errors which are either extreme lack of intelligence, or lack of honesty. An example would be that all work on site had to stop whilst they waited for a change order from USACE, and thus we have delayed them. Clearly in reality only certain elements (which in this instance are not on the critical path) had to be stopped. Scheduling tricks like this are littered all over, and so they have created a story which paints them as blame free.
Same learning point as above.
3. USAMRIID progress
3a. Temporary Cooling.
The application of the bio-containment coatings (paint) is on the critical path for construction. The paint has quite tight limits of temperature and humidity in which it can be applied. Currently the weather is hot and damp and so preventing the application of the paints in some areas. MTJV (lead contractor) has rights to use the permanent systems for temporary cooling. They are attempting to turn the system on before it is truly ready, and this is of concern as they are likely to do some damage. The insulation on the chilled water line is not yet vapor tight and so will condense water, remain damp then become mouldy. We have been directed not to tell them to stop, as they will then expect reimbursement for the delay, as it is difficult to prove their system is not ready, so instead I am closely monitoring to point out damage early and so prevent further damage.
Leaning point: easily measurable criteria are required at any decision point or control point (such as turning on the system or not). Contractors will negotiate and haggle over anything!
3b. Electrical Problem (tripping early)
The Central Utility Plant (CUP) provides all the electricity, steam and chilled water to all facilities on the camp. We recently had a problem with tripping the HV feeders. This resulted in a brief game of defensive finger pointing, with everyone checking their equipment and calculations whilst stating they were sure it was another person’s fault. It was eventually solved by the CUP raising their settings, though they were initially adamant that their settings were correct. I have been trying to get all the relevant data, for academic study, but each of the organizations are unwilling to share their data.
Learning point: Basic engineering is often clouded by politics, this slows progress.
3c. Commissioning Progress: Merrick Issue log
I have been leading the Corps management of the Merrick Issue log. Merrick is the commissioning agent for the construction and so they find many and varied problems. In order to generate the answers whilst keeping costs down, I am attempting to answer each question within our office before elevating it to the Architects and Engineers
3d. Differential Pressure sensor.
Due to the high containment nature of the building, each area has its air pressure controlled very accurately. I am solving some of the problems that have been found whilst installing this system, namely that the sensors may become “Pegged Out” during an equipment failure event, leading to a possible containment failure. Clearly this is unacceptable, it may require a $500K change order, I am investigating all methods to keep this cost down.
Learning point: All possible failure Conditions must be designed in, this will save money over the course of the project.
3e. Duct lining in 6th Floor.
In one of the mechanical areas there is insufficient space between the air handling unit and the duct directly above it to fit insulation. The insulation is required to prevent the duct condensing water during the hot moist weather that is common here. We are exploring solutions; the most likely appears to be adhesive duct liner that will insulate the inside of the duct. The customer and designer are reluctant due to the poor track record of duct liner for decaying and becoming flaky and brittle. We are having to explore all other methods, and also reassure the customer.
Learning point: information and expectation management is important to prevent the customer becoming concerned. Technology can move forwards but certain bad reputations will stay attached to the concept, in this case the new duct liner is proven to be adequate, but it is still a duct liner and thus considered a poor solution. This original problem could have been avoided by a 3D drawing and modeling package.
3f. Wall and Riser close ins
I have become the USACE plumbing lead for most of the ceiling and wall close ins.
3g. Plenum Walls inspection problems with QC
The air intake plenums for AHU’s have prefabricated sheet aluminum insulated walls. These have been allowed to corrode whilst in storage or transit, leaving a white substance on the surface. The quality control of the sub contractor and lead contractor both seem to have failed to stop this, so it has fallen on me and one of the other young engineers to perform some really low level QC.
3h. Pipe, pressure line and Duct tests
I continue to conduct pressure and flow tests on the various systems that are being installed, this includes Compressed air, Compressed Nitrogen, CO2, Water systems, Air ducts (both standard and bio-containment) and Air Handling Units
4. Other News
4a. Storms
We continue to have really good storms out here, almost tropical, with continuous lighting, we in fact got evacuated off site last Wednesday due to a storm warning, the office got hit by lightening, though no real damage done.
4b. Sarah’s Job
Sarah has managed to get a job lined up, so that’s a real relief for her as it has been a while. She is working for Randstad Recruitment, in an office that is ¼ mile from our house so very convenient. She is not that impressed with their working practices!
4c. Sarah’s playing in Carousel
Sarah has been involved in the local Frederick Towne Players, who are currently putting on a performance of Carousel. They are generally surprisingly good for a small town community theatre, but still have a few characters in the crew which make it funny!
4d. Bacon Sundae
As part of my cultural learning I am partaking in some of the local delicacies, most recently a Bacon Sundae. This is a Burger King Special, combining bacon and an ice cream sundae. It is as you would expect…
4e. July 4th Celebration
We had a great day off celebrating the American independence, being asked by Americans if it is a day of mourning back in the UK. They really go for it in a big way with the whole town in the Park for sunset fireworks.
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