Introduction

BHP Engineering & Construction, L.P. (BHP), with a home office in Corpus Christi, Texas and a branch office in Victoria, Texas, provides quality, responsive, and cost effective engineering and construction services to industrial, municipal, commercial, and military clients.
 

BHP has an experienced staff covering the process and chemical, civil and structural, piping and mechanical, control systems and instrumentation, electrical, environmental, and architectural disciplines. We are a multi-discipline, full-service design engineering and construction firm with a diversified staff of engineers, architects, planning/scheduling specialists, designers, computing technicians, surveyors, construction coordinators, and support personnel.

BHP has become known as a provider of high quality service (our main source of business comes from our satisfied, repeat clients), and has grown into the most advanced and largest engineering firm in the Coastal Bend. BHP is a progressive company utilizing leading edge state-of-the-art technology with a wide array of LAN and WAN equipment and resources. Our networked system provides access to a multitude of technical and

general software including AutoCAD and Intergraph Microstation. The majority of our work is drawn and designed utilizing computer-aided drafting and design engineering software package platforms.  In-house expertise is available in all of these engineering and consulting services and the water and wastewater treatment services are detailed to a greater extent in the following pages.

The precious and precarious balances in our ecological systems require constant monitoring of solutions for environmental safety. Rapid expansion of controls safety criteria and enforcement of regulations demand a thorough focus on all aspects of engineered solutions, among which are:

Water - BHP engineers can provide safe and economical solutions for all types of water treatment. Safe, potable drinking water is obviously most essential for today's people and cities, and good design of these systems is a high priority for BHP. Each phase of the system is engineered to provide highest quality drinking water.

Wastewater - Design of high quality, economical wastewater treatment systems is an essential element of our highly regulated society. BHP provides designs for effective solutions to these vital challenges in both the

industrial and municipal areas. High-strength soluble BOD wastewater is a particular area of expertise. Municipal systems are designed with high flexibility to adapt to the fast changing permitting requirements, and provide solutions starting with basic biological systems and extending to advanced secondary treatment and

including chlorination/dechlorination Chemical and physical methods of wastewater treatment can also be readily designed by BHP engineers. If the nature of the wastewater to be treated is unknown, treat ability studies may be done on a bench-top scale to provide necessary parameters for efficient design. BHP also offers expertise in all areas of sludge management and can provide microorganism identification if required.

Specialized Assistance – The staff at BHP is not only committed to the physical design of facilities but also has extensive operating experience. They can provide operating manuals and preventative maintenance management systems for environmental control process. BHP offers extensive expertise in the application of Personal Computers and Programmable Logic Controllers to the process control systems, SCADA and data gathering, and graphic interfaces for environmental systems. The specialized engineered solutions for environmental safety by BHP engineers are among the best in Texas.

Manufacturing - BHP Engineering and Construction has developed innovative technology and manufacturing capabilities in the field of reverse osmosis and integrated membrane systems. BHP has developed 16” diameter reverse osmosis technology that has many advantages:

Representative Projects

O. N. Stevens Water Treatment Plant Chemical Storage and Feed Upgrade
Project Cost: $6,000,000
Completion – In Progress (scheduled completion 2003)
City of Corpus Christi

BHP completed the design for the above tasks and is responsible for the construction inspection during installation

Boiler Feed Water Plant
Project Cost: $9,000,000
Completion – 2002
Flint Hills Resources

The project was built to provide ultra pure water to the 400# steam boilers at a local industrial complex.  The innovative process configuration used was a combination of ultrafilteration and reverse osmosis system.  The plant was designed to meet the following specifications:

BHP team provided complete engineering for the project including:

Wastewater Treatment System Study
Project Cost: $300,000 (Engineering Fee)
Completion – 1993
DOW Chemical Company

The objective of this study was to determine the short and long term wastewater system needs to stay in compliance with current and proposed regulations. Work also included wastewater characterization study of the entire facilities at source streams and combined flow streams. Results were used to define the Phase I Wastewater project to minimize RCRA impacts on the total wastewater treatment system. Two key concerns were the design of a replacement system of the high strength wastewater lagoons that were caught by the RCRA regulations and design of a replacement or method to control algae in the low strength wastewater lagoon systems caught by OCPSF regulations on TSS. Work included alternative evaluation, cost estimating, technology research, bench scale testing, and pilot testing, and managing other engineering subcontractors in addition to the primary subcontractor. BHP supervised a waste characterization study and wrote RFQ’s and managed bidding for the bench scale and pilot test scale. Pilot tests were to run on a DAF unit for TSS/algae removal and a SBR aerobic system for TSS/algae removal. Bench scale tests were run on high rate suspended growth and attached growth anaerobic reactors.

Raw Water Project
Project Cost: $18,000,000
Date Completed: 1992
DOW Chemical Company

BHP participated in preliminary engineering and design engineering of a new raw water pump station and re-route of canal conveyance system. Final project consisted of two large diameter concrete cylinder pipe suction pipes, large diameter discharge lines, 4900’ of open canal, eight sections of large diameter polyethylene pipe each, and flow control and transition structures. Pumping consisted of 8 pumps of various capacities matching variable seasonal demand cost effectively. The combined total connected horsepower was approximately 2,000 Hp. Key features included sonic flow meters, computer system with radio controls, submersible pumps, and use of large diameter poly pipe. Construction required installing 96” concrete cylinder pipe in a very soft and wet marsh area. An engineered movable interlocking pontoon type mat system was used to support heavy equipment. The Canal was constructed of local clays. This clay required some modification with lime to make it suitable for canal construction.

O. N. Stevens Water Treatment Plant SCADA Coordination
Project Cost: $100,000
Continuing
City of Corpus Christi

BHP is currently working with the City of Corpus Christi Water Treatment Plant to develop and maintain procedures for coordinating work practices and documentation procedures for the plant SCADA System. This has included developing engineering standards and recommending hardware revisions.

O. N. Stevens Water Treatment Plant Process Hazard Analysis
Project Cost: $38,000 (Engineering Fee)
Completion – 1999
City of Corpus Christi

BHP provided the Process Hazard Analysis facilitation and documentation using the HAZOP methodology for the hazardous materials process at the plant 

O. N. Stevens Water Treatment Plant Lime Unloading System
Project Cost: $200,000
Date Completed: 1998
City of Corpus Christi

BHP provided the design for the pneumatic conveying system and dust collection to unload lime from the trucks to the Lime Storage bins.

Phase 1 Wastewater Project - EP
Project Cost: $5,000,000
Date Completed: 1991
DOW Chemical Company

BHP provided the preliminary design, detailed design, and engineering work for wastewater pumping stations and pipelines. This project included designing a two-mile above ground polyethylene pipe routed through existing road and railroad culvert crossing to minimize cost. Existing wastewater lift stations, sumps and piping systems were carefully evaluated to insure new facilities would not require retrofitting existing lift stations and sumps with new pumps. Upgrade and improvements were recommended and designed to reduce overflowing of high strength sewer system lift stations. Work included:

Storm Water and Wastewater System Improvements
Project Cost: $4,700,000
Date Completed: 1992
Valero Refining - Corpus Christi, TX

BHP designed many storm water drainage systems, pumping systems and tank containment modifications and improvements to provide the plant site with effective Storm Water management capabilities.  An additional wastewater treatment Cooling Tower cell was designed and specified for wastewater temperature reduction.  New variable speed drives were designed for the wastewater treatment bioreactors.  A new Dissolved Air Flotation (DAF) was designed for addition to the wastewater treatment system along with associated piping, instrumentation, and electrical.  The new unit was equipped with a cover and a vapor recovery system.  An existing DAF unit was also recovered and equipped with a vapor recovery system.  A new corrugated plate Separator was designed along with a vapor recovery system and subsequent routing to an existing plant flare.  Existing Separators were also equipped with vapor recovery systems.

BHP designed a complete revamp of the Process Oily Water waste system from source to the equalization tank. The project included the conversion of an existing API Separator to lift stations and the installation of new Oil-Water Separators. A new skimmer vessel was added for the and a new complete CPI separation system. The design of the complete refurbishment of the Activated Sludge Water Treatment system was completed by BHP engineers and included digesters, land farming, pH control, etc. 

O. N. Stevens Water Treatment Plant Control Room Pressurization
Project Cost: $150,000
Completed 1997
City of Corpus Christi

BHP completed the design of a tempered air control room pressurization for the Water Treatment Plant control to provide a safe working environment for the plant operators.

Oilfield Produced Water Treatment
Project Cost: $6,500,000
Project in progress
Aera Energy

BHP provided conceptual study to treat 120,000 BBL/Day of produced water using hotline process, ultra filtration and reverse osmosis processes. In the reverse osmosis treatment, the new state of the art 16” Magnum R.O. Membranes are to be incorporated with the interstage fresh feed. The R.O. System is projected to have 30% savings in Capital costs and 25% savings in operation costs.

Ultrafiltration – Reverse Osmosis System
Project Cost: $3,000,000
Date Completed: 1999
City of San Diego, CA

BHP provided conceptual engineering, mechanical engineering and economic analysis for the system to treat waste water effluent to potable water standards for injection to ground water aquifer.

O.N. Stevens Water Treatment Plant Chemical Monitoring Project
Project Cost: $1,300,000
Date Completed: 1999
City of Corpus Christi

BHP did feasibility studies and designed a system to unload the Chlorine railcars and provide for spray mitigation for a Chlorine release. Also included were containment, a barrier wall, gas detection and shutdown, and a plant wide emergency alarm system. 

BHP provided the engineering design for a 20,000 gallon Liquid Ammonium Sulfate mix tank. The system consisted of a containment area, a pneumatic conveying system, a wet scrubber and an air agitated tank, and carbon filters.

BHP provided the engineering design and construction inspection for a 6400 gallon reactor for producing liquid Alum. The system consisted of secondary containment, an Aluminum Hydrate handling system, an acid resistant refractory lined, agitated vessel, a vapor scrubber, acid weigh tank, and new control room.

This cooling water system consisted of 6.6 miles of supply piping and 5.6 miles of return piping with 15 supply pumps with a total of 11,450 connected horsepower (pumps ranged from 500 to 1200 hp). Hydraulic modeling of supply and return systems was done using Cybernet software. The model was field calibrated. A study was prepared to list alternatives for phased upgrades to the entire system to meet future growth. The first phase of this project was to overhaul and rebuild all 15 pumps with out any cooling water disruption to this plant's production. This goal was accomplished along with improved materials of construction, improved pump efficiency (significant power savings), and an increased flow capacity average of 6800 GPM per pump. The project was completed on time and under budget.

BHP performed an engineering study to evaluate and identify problems and bottle necks and make recommendations for solutions in the cooling water piping system. The piping consisted of cast-in-place concrete pipe of 72-inch diameter, concrete steel cylinder pipe ranging in size from 12-inch diameter to and including 60 inch in diameter. Various methods of repair were recommended with the estimated repair cost included. Some of the lines were installed in 1954 and had begun to leak.

O. N. Stevens Water Treatment Plant Chlorine Feeder and Piping Revisions
Project Cost: $140,000
Date Completed: 1998
City of Corpus Christi

BHP designed the new Chlorine feeders, evaporator, and vapor side piping layout to provide increased simplicity and redundancy for the plant Chlorination process.

Temporary Disinfection for the City of Corpus Christi Allison, Broadway, Laguna Madre, and Oso Wastewater Treatment Plants
Project Cost: $600,000
Date Completed: 1999
City of Corpus Christi

Facilities installed for temporary Chlorination - Dechlorination at the above mentioned plants to remove hazardous materials from the plant sites. This was a schedule driven project that required coordination with the contractor and equipment manufacturers and was completed on schedule.

Permanent facilities were designed to replace the interim Chlorination - Dechlorination at the above mentioned plants. Included in the design were new bulk storage tanks and secondary containment for the Sodium Hypochlorite and the Sodium Bisulfate used for the treatment process. Also included were improved feed injection systems.

PDES & TNRCC Permitting
Project Cost: $20,000 to $30,000 (Engineering Fee)
Date Completed: Varies 1990 through 1995
DOW Chemical Company

BHP has experience with both municipal and industrial permits. Typical services provided are listed below. BHP provided technical assistance, cost estimates, for compliance options, and writing statements and arguments supporting the clients’ positions based on performance data, scientific, and engineering studies. BHP provided background and historical data for effluent permit limit calculations. BHP helped client with comments to draft permit issued by the EPA. BHP client determined impact of final permit and assisted in preparing a request for an evidentiary hearing. BHP scheduled work, supervised preparation of drawings and data required for the permit, obtained clarifications on requirements from consultants & TNRCC, wrote sub-contracts for research work, wrote report sections, and coordinated data collection required for permits

Wastewater Lagoon Project
Date Completed: 1994
DOW Chemical Company

BHP participated in preliminary engineering and design of a wastewater treatment lagoon meeting MTR requirements. In addition to the double liner, this project included design of a flexible membrane cover for odor and emissions control.

Constructed Wetlands Project
Project Cost: Approximately $80,000
Date Completed: 1994
DOW Chemical Company

BHP participated in a design of a constructed wetlands wastewater treatment system for as groundwater remediation project. The project included design of a double polyethylene liner with a leak detection system for installation in an existing rectangular concrete basin. This process was selected to provide a passive, reliable, and low cost method to treat this waste stream.

O. N. Stevens Water Treatment Plant Filter Media Replacement Project
Cost: $2,500,000
Completed 2001
City of Corpus Christi

BHP participated in the design of complete replacement of the media in 22 filters. It also included new underdrains and air scour capability for 10 of the filters.

O. N. Stevens Water Treatment Plant High Service Pump Addition
Project Cost: $4,500,000
Completed – In Progress (scheduled 2003)
City of Corpus Christi

BHP participated in the design of an additional pump for the High Service # 2 pumping facility. Included in the project were a new variable speed pump, replacement of three existing pumps and motors, 1500 feet of pipe rack, 2 new Power Control Rooms, additional fiber optic data highway cable, and several new PLCs with some remote SCADA I/O chassis.

BHP participated in the design of revisions to the Filter Wash Water system at the Plant. The project included addition of Filter to Waste capabilities on all 22 filters, a new wash water supply pumping station, a new elevated wash water supply tank, a wash water reclaim pumping station, 2000 feet of pipe rack, a new Power Control Room, flow measuring and control improvements, new turbidity analyzers, new local control consoles on ten filters, 3 new PLCs with remote SCADA i/o chassis, automated filter backwash logic, and new fiber optic cable.

Diffuser Dye Study
Project Cost: $15,000 (Engineering Fee)
Date Completed: 1995
Formosa Plastic Corporation - Point Comfort, TX

This study was undertaken to compare dye testing and salinity in a side by side test. The results of the two procedures were similar. Salinity testing was selected because no chemicals are added to the effluent and conventional sampling equipment can be used to collect the field data needed.

Diffuser Validation Study
Project Cost: $20,000 (Engineering Fee)
Date Completed: 1993
Formosa Plastic Corporation - Point Comfort, TX
 

BHP completed the requirements in Formosa’s NPDES permit to determine the best method to confirm compliance with the specified diffuser dilution criteria. Work included review of previous studies and reports, review of diffuser design and performance prediction software, and the development of the testing procedure. BHP also assisted Formosa’s staff during the actual sampling then prepared a final report. Salinity was selected as the primary indicator of the diffuser performance. It was also recommended that all data required to run the Cormix model be collected so it could be ran as a verification and clarification of the salinity results.