FROM: Robert Thompson, General Manager
Originator: Riaz Moinuddin, Director of Operations & Maintenance
SUBJECT:
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PROCUREMENT OF COOPER LSVB INTAKE MANIFOLDS AT PLANT NO. 1
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GENERAL MANAGER'S RECOMMENDATION
recommendation
RECOMMENDATION:
A. Approve a Sole Source Purchase Order to Cooper Machinery Services, LLS for the procurement of two spare air intake manifolds for three engines in Central Generation at Plant No. 1 for a total amount not to exceed $242,431, including applicable sales tax & freight; and
B. Approve a contingency of $24,243 (10%).
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BACKGROUND
The Orange County Sanitation District (OC San) operates three clean-burn internal combustion engines that generate electricity at the Plant No. 1 Central Generation (Cen Gen) facility. Cen Gen also provides process heat to the digester complex at Plant No. 1. They also use methane-rich digester gas produced during wastewater treatment, reducing emissions and supporting compliance with South Coast Air Quality Management District permit requirements.
CenGen engine components must meet original equipment manufacturer (OEM) specifications to maintain performance, efficiency, and emissions compliance. Air intake manifolds are critical engine components that distribute combustion air to the cylinders. A damaged or failed manifold can disrupt airflow, cause uneven combustion, increase emissions, and result in an engine shutdown. Maintaining spare manifolds is necessary to support reliable CenGen operation.
RELEVANT STANDARDS
• Operate and maintain facilities to minimize impacts on surrounding communities, including odor, noise, and lighting
• 24/7/365 treatment plant reliability
• Maintain a proactive asset management program
PROBLEM
OC San does not currently have spare air intake manifolds for the three engines at Plant No. 1 CenGen. The existing manifolds have experienced wear and require minor crack repairs, increasing the risk of an unplanned engine outage if a manifold fails.
PROPOSED SOLUTION
Approve a Sole Source Purchase Order to procure two spare LSVB Air Intake Manifolds for the Cooper Bessemer engines at Plant No. 1 to maintain asset availability and minimize process downtime.
TIMING CONCERNS
The air intake manifolds have an estimated manufacturing and delivery lead time of approximately 25 weeks. Procuring the manifolds while the existing units remain serviceable will reduce the risk of an extended engine outage resulting from an unexpected failure.
RAMIFICATIONS OF NOT TAKING ACTION
Without spare air intake manifolds, a manifold failure could result in an extended engine outage while a replacement is manufactured and delivered. Given the estimated 25-week lead time, the loss of an engine could significantly affect electrical reliability, digester heating capability, emissions performance, and OC San's ability to maintain permit compliance.
PRIOR COMMITTEE/BOARD ACTIONS
August 2017 - Approved Cooper Bessemer (Cooper Machinery) as an Original Equipment Manufacturer (OEM) Sole Source provider for CenGen engine components.
ADDITIONAL INFORMATION
Cooper Machinery Services LLC is a Board of Directors-approved OEM vendor for all CenGen engine components. A 10% contingency is requested in the event of pricing changes due to tariffs, delays in placing the order beyond valid quote dates, or other unforeseeable changes.
CEQA
N/A
FINANCIAL CONSIDERATIONS
This request complies with the authority levels of OC San’s Purchasing Ordinance. This item is budgeted (Budget FY 2026-27 and 2027-28, Section 6, Page 128, Repairs & Maintenance) and the budget is sufficient for the recommended action.
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Date of Approval |
Contract Amount |
Contingency |
|
09/2/2026 |
$242,431 |
$24,243 (10%) |
ATTACHMENT
The following attachment(s) may be viewed online at the OC San website (www.ocsan.gov) with the complete agenda package:
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