Engineering & Project Management - The Brightwater Tunnel

BRIGHTWATER TUNNEL

Project: Large Infrastructure Location: King County, Washington United States Project Manager: Morgan Raman

BRIGHTWATER TUNNEL

Project: Large Infrastructure Location: King County, Washington United States Project Manager: Morgan Raman

At $1.86 billion, the Brightwater Tunnel project is one of the largest infrastructure expansion projects completed in the United States.

It was a part of the rapid urban development around the city of Seattle, Washington.

In my role as the Project Manager of the Americas with Future Pipe Industries, I led a manufacturing team and collaborated with the international joint venture of Vinci-Parsons-Frontier-Kemper from developing requests for proposals to project closeout through construction ensuring project completion within budget, and on time.

Project Summary In 2012, King County in Washington State built a $1.86 billion expanded 13-mile tunnelled effluent conveyance system collectively referred to as the Brightwater System. This infrastructure system was built to address the rapid urban development around Seattle, in north King County and south Snohomish County, which included the neighboring cities; additionally, it was designed to accomodate outflow from the pre-existing effluent network. The tunnel depth ranged from 50-ft to 450-ft below ground, along varying, complex ground profiles. It was constructed by the strategic deployment and synchronized operations of multiple tunnel boring machine (TBM) systems.

In my position as the Project Manager of Americas at Future Pipe Industries, and as the Owner’s Representative, my team was the manufacturer-of-record with the global joint venture partner Vince-Parsons-Frontier-Kemper in multiple phases of this project. From RFP to closeout, our team developed proprietary designs of very large diameter fiber-reinforced pipes (FRP) and innovated stringent strength/structural stability tests beyond ASTM requirements to meet specific project needs. I deployed a fractal agile manufacturing process for product development including, prototyping, testing, and delivery and addressed the logistics for multimodal transportation methods to deliver the manufactured product in tandem with the tunnel construction progress. Through effective communication with the JV partners Four construction areas called portals were used to build the and improvisation in real-time to adapt to the fast project pace tunnels. A complex network of pipes and associated systems and its ongoing technical changes/challenges, the project was were installed into the tunnel that addresses both influent and delivered on time. effluent flows, linking them to various treatment plants, pump stations, and regulator stations to handle millions of gallons of diurnal influent and effluent transport, treatment, and final discharge into a confined marine exit in Puget Sound leading ultimately to the Pacific Ocean.

Existing Conditions The map shows details of existing systems and effluent pipeline networks prior to the Brightwater project. Nearly 250 million gallons per day (MGD) of effluent was processed by the various treatment plants strategically located around the various water bodies to serve metropolitan Seattle and its surrounding suburban areas. The rapid urban growth area shown on the map necessitated an expansion of the current system with the Brightwater Tunnel traversing east to west along the King County and Snohomish County lines, linking the various existing systems and expanding the infrastructure for the next 50 years.

The geological mapping and tunnel alignment profiles and cross-sections are shown in the upcoming pages including the process deployed for product manufacturing specific to the project.

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1 Bothell

SNOHOMISH COUNTY KING COUNTY

Sou n d

Woodinville

Alki

is h

am

Pug

et

Seattle

Bellevue

L a k e Sa m m

2

L a k e W a sh in gt o n

Carkeek

Issaquah WA

4

Renton

3

Vashon Island

Effluent Pipeline Network Urban Growth Area Boundary Flow Transfer Area CSO Treatment Plant

Effluent Treatment Plants

1 City of Edmonds (exist., flow transfer) 2 West Point 133 MGD 3 Vashon Island 0.26 MGD 4 South 115 MGD

East Service Areas

TY TY UN UN CO CO NG E KI ERC PI

Federal Way

Pump stations

West Service Areas Regulator stations Pump stations 0 miles

2

4

N

WOODWAY

EDMONDS

UNINCORPORATED SNOHOMISH COUNTY

99

MOUNTLAKE TERRACE

104

5

Lake Ballinger

Marine Outfall

SNOHOMISH KING

104 99

lli

SNOHOMISH

ng er

un

ay W

SHORELINE

9

)

nt

NE

P

oi

s P o rta

l (1

Ba

W e ll

lli

ng

LEGEND

5)

So

KING

d

1 9t h Av e NE

5 Ba

Pu g e t

Richard Beach Dr.

Puget Sound

e r Wa y P o rta

l(

LAKE FOREST PARK

Effluent conveyance

BRIGHTWATER TUNNEL HORIZONTAL ALIGNMENT

PUGET SOUND

LAKE WSHNGTN

Surface projection of tunnel alignment Tunnel Portal locations

PERSPECTIVE VIEW OF THE BRIGHTWATER CONVEYANCE SYSTEM ALIGNMENT IN KING/SNOHOMISH COUNTIES, WASHINGTON STATE

Photo credit: King County, WA Addl info added by author

600

5 400 D E P T 200 H

Geological Profile

600

405 400

200

0 FT tunnel vertical alignment design was based on the subsurface geologic profile along the proposal length.0 FT The Meandering through surcharge depths varying from as a shallow as 50 ft to over 450 ft in some locations, the -200 20,000 30,000 40,000 sediment 50,000 60,000 tunnel was built in 10,000 strata comprising older glacial/non-glacial deposits, infill, and alluvial deposits.67,000 The-200 0 1 MILE at the top of 3the MILEpage shows the 5 MILE 7 MILE 9 MILE 11 MILE 13 MILE perspective view terrain and a surface view of the horizontal alignment of the tunnel GROUND PROFILE AND GROUND WATER TABLE ALONG PROPOSED TUNNEL ALIGNMENT in the difficult mountainous terrain of Washington State.

D E P

600

600

400

400

Infl

BRIER

BOTHELL

UNINCORPORATED COUNTY

7 Treatment Plant Site

Ke n

m o re Po rt

al

405

(

N

or

Cr e e k P o r t a l (

80t h Av e N E

No rth Cre e k Pk w y

N E 1 95 th

th

N E 1 92n d

4

1)

rth

) 44

No

527

NE 1 95th St

WOODINVILLE KENMORE UNINC. KING COUNTY

PUGET

Lake SOUND Washington

fluent conveyance

N

BOTHELL

Sammamish River

LAKE WSHNGTN

0

522

Surface projection of tunnel alignment Tunnel Portal locations

405

WastePERSPECTIVE water service area Outfall pipe Flow transfer area boundary County line VIEW OF THE BRIGHTWATER CONVEYANCE SYSTEM ALIGNMENT IN KING/SNOHOMISH COUNTIES, WASHINGTON STATE 600

405

400 D E P T 200 H

400

0 FT

0 FT

200

-200

10,000 0

1 MILE

20,000

30,000

3 MILE

5 MILE

40,000 7 MILE

50,000 9 MILE

60,000 11 MILE

67,000

-200

13 MILE

GROUND PROFILE AND GROUND WATER TABLE ALONG PROPOSED TUNNEL ALIGNMENT

600

600

400 D E P T 200 H

400

0 FT

0 FT

200

-200

10,000 0

1 MILE

20,000

30,000

3 MILE

5 MILE

40,000 7 MILE

Fill and Alluvial deposits Older Non-glacial deposits

Alluvial and Non-glacial deposits: Generally sands, silty sands, and gravel

50,000 9 MILE

Glacial deposits: Generally till, lacustrine and outwash

60,000 11 MILE

67,000

-200

13 MILE

Voshon Glacial deposits Older Glacial deposits

GEOLOGIC SECTION ALONG PROPOSED TUNNEL ALIGNMENT

600

600 E X C A V A T I O N

5

405

400 D E P 200 T H

400

0 FT

0 FT

200

-200

10,000 0

1 MILE

20,000 3 MILE

Sand, Gravel (outwash) Silt/Silty sand (till/alluvium)

30,000 5 MILE

Hard Clay

40,000 7 MILE

Tunnel Hydraulic Grade Line

50,000 9 MILE Surface water bodies Ground water table line

SIMPLIFIED GEOLOGIC SECTION AND TUNNEL VERTICAL ALIGNMENT

60,000 11 MILE Tunnel Portals

67,000

½

City boundary

600

5

¼ miles

-200

13 MILE

Product description Product Engineering Team Project Management Team

Inputs Phases

INITIAL

Project Management Outputs

Scope Charter

INTERMEDIATE FINAL Production Acceptance Plan Prototype QA/QC

Project Deliverables

Approval Deliver

Product Transport Logistics

PROJECT LIFECYCLE PHASES FOR PIPE MANUFACTURING

INITIAL Planning: Vision, Product Protocols

Prototype Development Planning

INTERMEDIATE

AGILE

First Prototype

Second Prototype

Third Prototype

Project Retrospective

Project

Iteration

Iteration

Iteration

Prototype Retrospective

Prototype

Prototype Retrospective

Iteration

Daily work: Iteration Planning

FINAL

Design Simulate Produce Test

Daily work:

Design Simulate Produce Test

Daily work:

Design Simulate Produce Test

PHASES/SUBPHASES IN AGILE MANUFACTURING PROJECT LIFECYCLE

Project Management | Agile process for prototyping, manufacturing, and delivery For the Brightwater Project, I established a team consisting of production, chemical, and manufacturing engineers to develop a proprietary product composition specific to the project

needs. Pipeline manufacturing is definable work from a project management perspective. However, for this project, there were no benchmarks of proven successful projects in the past leading

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MANUFACTURING SCHEMATIC

Continuous Rovings Separator Combs Resin Bath

Nip Rollers Guide

Rotating Mandrel

Creel

A–A A psi A

psi

Agile Manufacturing Environment

Start

TESTING SCHEMATIC

to high-uncertainty work and therefore, high rates of change, manufacturing to quickly adapt based on test results and feedback complexity, and risk. I developed short-cycle methodologies for from stakeholders. manufacturing and testing to explore the feasibility of large-scale

Cross-sections | Urban scale and details The images on this page show the context of the installed pipeline ground activities. Local connections to the new pipeline were in an urban environment. All construction work in the urban areas made as individual city contracts to smaller companies handled was carried out underground with minimal disruption to above- directly by the respective cities.

11

1 8

50 — 450

2

ft

3

4

7

6

5

1

0

1

Looking East

1. Fiber Optic Cables 2. Precast Concrete Lining System 3. Structural Slab Backfill Class D-1 4. 54-in ID Influent Pipe

5. 24-in ID Raw Water Pipe 6. Backfill Concrete 7. 72-in ID FRP Effluent Pipe 8. Cunette

2

13

Tunnel Portals The overall construction of the tunnel comprised of four tunnel portals designed as strategic location points to commence tunnel boring operations or to establish tunnel breakthroughs at the end of a boring operation. The portals were also the delivery points for all construction materials, tunnel structural segments, pipes, and construction personnel.

Portals were constructed using ground-freezing technology for ground support with monitored operations of geotechnical conditions, groundwater response, shaft deformation, and subsoil temperature development.

Tunnel Construction The tunnel wall is composed of sixteen concrete modular segments assembled in tandem with the TBM progression.

(Top left) Construction progress in tunnel portal.

(Above Right) Assembly of the TBM in the portal.

(Far left) Completed tunnel wall.

(Left) Tunnel arch segments at staging area.

Photo credit (all): King County, WA

Large Infrastructure | Treatment facility and marine outfall The Brightwater treatment plant has a processing capacity of 36 process to treat the wastewater to ultra-filtration. With future MGD (163,000 m3/day) on average and is designed to resist a 7.3 expansion integrated into the plant design, its treatment capacity magnitude earthquake. The design uses a membrane bioreactor can be increased to 54 MGD (245,000 m3/day) by 2040. It

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Photo credit: King County, WA

Photo credit: Hoffman Construction

is located in the unincorporated region of Snohomish County, comprised of two 60-inch diameter pipes that run a mile long, north of the City of Woodinville and occupies 114 acres (46 ha) 600-foot outfall into the Puget Sound, where highly treated with a plant footprint of 43 acres (17 ha). The marine outfall is wastewater from the treatment plant is discharged.

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End of Document

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