Northeast Water Purification Plant (NEWPP) Expansion | WWD Weekly Digest

Summary

This interview dives into the massive Northeast Water Purification Plant expansion in Houston, Texas, with key figures from McCarthy Building Companies and Houston Water Works. The $1.8 billion project aims to boost the city's water treatment capacity, with an emphasis on the construction of a massive intake pump station. Challenges such as logistical issues, storm events affecting water quality, and the complexities of building on a lake were tackled through innovative solutions and strong teamwork. Safety was prioritized throughout, leading to 250,000 man-hours with zero accidents. The project highlights the collaboration of thousands of professionals working toward a vital infrastructure goal.

Takeaways

• 😀 The Northeast Water Purification Plant Expansion project is a massive $1.8 billion initiative aimed at enhancing Houston’s water supply for the northern and western service areas.
• 😀 The Intake Pump Station, a key part of the project, costs $75-80 million and is capable of pumping 320 million gallons of water per day through six large vertical turbine pumps.
• 😀 The project involved up to 1,500 workers on-site daily, with a total of 5.6 million man-hours worked and zero lost-time accidents, highlighting the strong focus on safety.
• 😀 The project was delivered using a progressive design-build method, with McCarthy Building Companies selected as the contractor after a competitive bidding process.
• 😀 A unique challenge was the site’s location: the pump station is constructed on a concrete slab floating 1,000 feet over Lake Houston, requiring specialized construction techniques.
• 😀 The Intake Pump Station’s construction involved advanced marine construction elements, such as dredging, piling, and structural work on a floating slab.
• 😀 The project is closely tied to the Luce Bayou Interbasin Transfer Project, which ensures a steady water supply by adding water from the Trinity River into Lake Houston.
• 😀 One of the major environmental challenges was dealing with fluctuating water turbidity and alkalinity due to the lake's shallow depth and seasonal weather changes.
• 😀 To mitigate issues with water quality, the team implemented tailored coagulation recipes for wet and dry weather conditions to ensure effective treatment.
• 😀 The pipeline design accounted for significant temperature fluctuations and expansion/contraction, using flexible couplings to manage the stress on the pipes and ensure long-term stability.
• 😀 A key safety strategy involved creating detailed, visual work plans to overcome communication barriers, ensuring that all workers, including non-English speakers, understood the procedures and risks.

Q & A

What is the overall size and scope of the Northeast Water Purification Plant expansion project?

The Northeast Water Purification Plant expansion project is a $1.8 billion infrastructure investment for the city of Houston and its regional water authority partners. The intake pump station alone, which is part of this larger project, costs $75-80 million.

What project delivery method was used for this expansion project and why?

The project was delivered using a progressive design-build method. This approach was chosen to provide flexibility in design and construction, ensuring that the project could be adapted and optimized as the work progressed.

How does McCarthy Building Companies contribute to this massive project?

McCarthy Building Companies serves as a key subcontractor for the Houston Water Works Team, particularly focusing on the intake pump station. Their role involved bringing together expertise in marine, water, and commercial building components to execute the complex construction, which includes massive structural components and dredging.

How does the Northeast Water Purification Plant expansion relate to the Loose Bayou Interbasin Transfer Project?

The Northeast Water Purification Plant expansion relies on the Loose Bayou Interbasin Transfer Project to supplement its water supply. The transfer project pumps water from the Trinity River watershed into Lake Houston, which is then drawn into the intake pump station for treatment.

What challenges did the project face with the raw water source, and how did the team address them?

The project faced challenges due to the 'flashy' water phenomenon, where rainfall dramatically changes the water quality in Lake Houston. This led to issues with alkalinity and turbidity. The team adapted by using different coagulation recipes to maintain water quality, depending on weather conditions.

What specific logistical challenges did the construction team face when building the pump station on Lake Houston?

The construction of the pump station faced significant logistical hurdles due to limited access to the site, the massive scale of materials being delivered (such as large pipes and concrete), and the need to transport everything over narrow, mile-long stretches of land. Additionally, COVID-19 added complications by limiting in-person meetings, which made coordination more challenging.

How did the team address safety concerns with such large-scale equipment and construction on the lake?

Safety was a top priority throughout the project. The team used detailed work plans, peer reviews, and extensive communication with subcontractors and workers to ensure safety. They also employed visual communication methods, such as color-coded systems and step-by-step diagrams, to ensure that all workers understood the procedures and dangers involved.

How did the construction team manage the expansion and contraction of the massive pipes used in the project?

The team accounted for the expansion and contraction of the pipes due to temperature changes by using flexible couplings along the entire length of the pipeline. These couplings allowed the pipes to expand when heated and contract when cold, which was crucial, especially since the pipeline runs across an exposed area in the lake.

What role did subcontractors and partners play in the success of the Northeast Water Purification Plant expansion?

Subcontractors and partners, such as Walker Engineering (handling electrical work) and Mid-America Pipe, played critical roles in ensuring the project's success. Their contributions, alongside McCarthy and the Houston Water Works Team, ensured the project was completed safely, on schedule, and to a high standard of quality.

How did the team maintain safety despite the complex logistics and large scale of the project?

The team maintained safety by ensuring thorough planning and review at every stage. They made use of safety protocols like detailed work plans, internal and external peer reviews, and visual communication tools to ensure that everyone, including non-English-speaking workers, was aware of safety measures. The project achieved over 250,000 man-hours with zero lost time or recordable incidents.