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Engineers recommend building a new Bob Darrington wastewater plant after condition assessment finds widespread deterioration
Summary
A multi‑disciplinary condition assessment of Odessa’s Bob Darrington Water Reclamation Plant found structural decay, corroded oxidation ditches, obsolete electrical systems and reduced effective treatment capacity; engineers recommended constructing a new facility (phase 1 sized to the city's 12.7 MGD permit) with a preliminary construction estimate of $325M–$350M and a staff RFQ to follow.
Corolla Engineers presented the results of a condition assessment, process evaluation and facility master‑planning first phase for the Bob Darrington Water Reclamation Plant at the City of Odessa’s Dec. 9 work session, and concluded that the plant requires major capital investment and likely replacement.
Project manager Hajma Salim, process lead Toshio Shimada and design manager Steven Mendoza said the plant is largely composed of assets from the 1970s and early 1990s. Field inspections and document review showed structural deterioration (concrete spalling, settlement cracking), severely corroded oxidation ditches, unsafe walkways, obsolete motor control centers (some older than 30 years), PLCs that do not report to SCADA, and single points of failure in chlorine contact basins.
A capacity/process evaluation found that wastewater concentrations for certain pollutants have increased since original design: biochemical oxygen demand (BOD) was reported 22% higher and ammonia 75% higher compared with the older design basis, reducing the effective treatment capacity. Hydraulically and process‑wise, several process units do not meet peak flow requirements and current and future Texas Commission on Environmental Quality (TCEQ) limits; engineers said the plant’s permitted average is 12.7 million gallons per day (MGD) but current average flows are about 7 MGD.
Corolla recommended a phased replacement master plan built adjacent to the existing plant so operations can continue during construction. Phase 1 would replace the plant at the existing permitted 12.7 MGD capacity while providing improved peak‑flow handling; subsequent phases would add capacity as demand increases (phase 2 anticipated about 10 years after phase 1). Recommended work includes new headworks with screening, two activated‑sludge trains with clarifiers, new filtration and disinfection to meet reuse standards, a belt‑press dewatering facility, repaired storage basins and full electrical/I&C upgrades to meet current codes.
Preliminary cost estimates given to council put construction for the new plant (Phase 1) in the range of about $325 million–$350 million in current dollars. Engineers cautioned those are planning estimates and that long lead times for major electrical switchgear (12–18 months) and code upgrades could affect schedule and cost. Corolla proposed an aggressive but achievable design schedule of roughly 24 months and then competitive procurement; staff said they will advertise an RFQ for design services (anticipated 60‑day advertisement) and return to council to authorize negotiations with a selected firm.
Council asked whether Odessa could afford not to proceed; city leaders and engineers said the plant faces structural, safety, process and regulatory risks that make action necessary. Staff discussed potential financing sources including loans and grants, and noted that Odessa’s local wealth may reduce eligibility for some grant programs while reuse revenues could help fund projects.
What’s next: staff to issue an RFQ for engineering/design, seek funding options, and return to council with a recommended contract for design and a project schedule; council thanked plant staff for keeping operations running during the assessment.
