Chris Hayden Project Profiles 12 2011

CONTACT INFORMATION

Christopher S. Hayden, [email protected]

561 Congress Park DriveDayton, OH 45459 USA

937-438-3010 Phone937-776-7899 Mobile

Christopher S. Hayden’sChristopher S. Hayden’s

Project Experience withProject Experience with

Htec Systems, Inc.Htec Systems, Inc.

ENVIRONMENTAL INDUSTRIAL SYSTEMS INTEGRATION

www.htecsystems.com

Industrial Process Engineering & Construction

Wastewater Treatment Plants: International Pepsi Locations

Shen Zhen, Guangzhou, Fuzhou, Shanghai, Nanchang, Beijing,

Chengdu, China

Jundiaí, Brazil

Buenos Aires, Argentina

Toa Baja, Rio Pedras

Puerto Rico

Michow, Znin Poland

Moscow, Samara, Yekaterinburg, Russia

Colonia, Uruguay

Irbid, Jordan

Philippines

Caracas, Venezuela

Bangkok, Thailand

Sidney, Australia

Bucharest, Romania

Htec Systems has designed over 20 wastewater treatment plants for

internationally located Pepsi plants (various franchises) over the last

three decades.

Htec Systems has designed over 20 wastewater treatment plants for

internationally located Pepsi plants (various franchises) over the last

three decades.

Ohio, New Jersey, New York

USA


Wastewater Treatment Plant: Pepsi-Cola & National Brand Beverages, New Jersey, USA

Htec Systems was selected to replace an existing wastewater treatment plant (WWTP) with a new system of greater treatment capacity. Htec was successful in partially constructing the new WWTP and placing it into service to provide sufficient treatment (Phase 1) so that the old system (including existing structures, piping, mechanical, electrical) could be removed. The remainder of the system was then installed (Phase 2). Htec worked closely with the mechanical and electrical contractors to supervise the switch-over.

The WWTP consisted of a pumping station, an Equalization Tank with pH adjustment and nutrient addition, a Trickling Tower Sump (for T.T. recycling), a Trickling Tower, an Aeration Tank and a Clarifier.

An Allen-Bradley ControlLogix PLC and a PanelView Plus was used to operate the WWTP.

Rotary Distributor Biological Growth ControlLogix

Steel-Bolted Tanks


Wastewater Treatment Plant: PepsiAmericas, Bucharest, Romania

In 2009, PepsiAmericas contracted Htec Systems for the design, major equipment selection and delivery, installation supervision, startup and training of a new wastewater treatment plant (WWTP) just outside of the city limits of Bucharest, Romania on highway A1.

The WWTP consisted of: Pumping Station, Equalization Tank, Anaerobic Reactor, Control Building with equipment room and laboratory, Submerged Biofilter, Aeration, (2) Clarifiers, Discharge Flume Tank.

The plant's average flowrate was 150 cubic meters/hour with a Biological Oxygen Demand (BOD) loading of 5,900 kg/day.

Htec was on site from January '09 until September '09 and interfaced with the general contractor, all subcontractors (elect, mech, piping), the PepsiAmericas construction manager and PepsiAmericas production staff.

The control system utilized all IEC electrical components (European CE rated), Siemens S7-300 PLC and a Siemens MP-377 Touchscreen terminal running Siemens WinCC HMI software.


Htec Systems provided standardized, modular wastewater treatment systems at over 20 PBG facilities around the United States. The treatment systems are designed to maintain the wastewater effluent pH within the limits established by local regulatory requirements.

In addition to the systems, Htec completed the detailed site engineering, permitting and installation unique to each plant. Htec provided site supervision, startup and training.

Htec continues to provide process maintenance support through scheduled site visits, phone support and equipment replacement.

A remote computer is installed to monitor the process and to log sensor data to an SQL database. Data is kept for two years.

Plant locations included Jacksonville, FL; Tampa, FL; Orlando, FL; Atlanta, GA; Knoxville, TN; Nashville, TN; Newport News, VA; Philadelphia, PA; Williamsport, PA; Harrisburg, PA; Johnstown, PA; Baltimore, MD; Wilmington, DE; Cranston, RI; Auburn, ME; Omaha, NE; San Antonio, TX; Houston, TX; Minneapolis, MN; San Diego, CA.

Wastewater pH Control Systems: Pepsi Bottling Group, Somers, New York, USA


From 1996 to 1997, Htec Systems supplied the complete process design for three WWTPs in Moscow, Samara, and Yekaterinburg, Russia. The designs included plant and equipment layout, mechanical/piping/electrical, PLC & Wonderware software programming and wastewater testing laboratory design.

For the WWTP equipment, Htec developed the specifications, procured all equipment, supervised the consolidation and packaging, generated all necessary shipping documents and supplied the GOST standard certificates so that that equipment could enter the Russian Federation.

Htec was based in Moscow for 16 Months and supervised all equipment installation, coordinated the works of all contractors, commissioned each plant and trained operators. O&M manual was supplied in Russian.

Each WWTP consisted of a Pumping Station, Caustic Holding Tank for bottlewasher caustic dumps, BioFilter, Equalization Tank, pH control, Activated Sludge, Aerobic Sludge Digestion, Sludge Thickening and Pressure Sludge Filtration.

Wastewater Treatment Plant: Pepsi International Bottlers, Russia

Moscow

Samara

Yekaterinburg


In 1996, Htec Systems was retained to design, install and commission a bottlewasher rinse water reclamation system for the Pepsi-Cola franchise bottler in Brazil. The BAESA bottling plant in Jundiaí consisted of four non-returnable lines and three returnable lines consisting of glass and PRB. Water was very expensive, $2.00/m3, and supply was predicted to decrease in the future. To conserve water and reduce costs, a reclamation system for the bottlewashers was designed and installed.

The system consisted of two holding tanks, a diatomaceous earth filter, pH control with CO2, an evaporative fluid cooler and chlorine addition. The bottlewasher rinse waters were pumped 150 meters to a raw water tank, where pH was adjusted and chlorine was added. The neutralized water was then filtered and passed through the cooler to reduce the temperature below 30 °C to a filtered water tank. The water was pumped through a hydro-pneumatic tank back to the bottlewashers. The system was controlled by a central PLC and remote I/O.

Water Reclamation System: BAESA, Jundiaí, Brazil


A local automotive wastewater treatment plant was equipped with 20 year-old technology. The PLC system was periodically failing and most analog instrumentation no longer worked. Htec Systems performed a complete electrical wiring audit to: 1 - identify functional and non-functional systems; 2 - compare electrical design drawings to the actual electrical installation. Htec Systems then completed detailed electrical design for the new PLC control system, instrumentation specifications and equipment budget estimates. All old and non-functioning equipment (PLC, strip-chart recorders, old instrumentation, selector switches, etc…) was removed and the new PanelView and Wonderware HMI based control system was installed “on-the-fly” while the operators maintained 100% control of the wastewater treatment plant. Full plant control was returned to the operators and additional functionality was added based on the operators’ feedback.

Wastewater Treatment Plant Control System Upgrade: Dayton, Ohio, USA

Panelview 1DH+ Addr 02Panelview 1Panelview 1DH+ Addr 02DH+ Addr 02


Computer 1Windows 2K

w/ WonderwareDH+ Addr 00

Computer 1Computer 1Windows 2KWindows 2K

w/ Wonderwarew/ WonderwareDH+ Addr 00DH+ Addr 00





Remote IO

Chassis 2

Remote IORemote IO

Chassis 2Chassis 2

Remote IO

Chassis 3

Remote IORemote IO

Chassis 3Chassis 3

Powerflex 70AC Drive

Remote IOChassis 4

Powerflex 70Powerflex 70AC DriveAC Drive

Remote IORemote IOChassis 4Chassis 4


Remote IOChassis 5



DH+ Addr 17Channel 1A

Allen-BradleyPLC5/40

Processor

RIO Chassis 1Channel 1B

DH+ Addr 17DH+ Addr 17Channel 1AChannel 1A

AllenAllen--BradleyBradleyPLC5/40PLC5/40

ProcessorProcessor

RIO Chassis 1RIO Chassis 1Channel 1BChannel 1B

DH+ Network

Remote IO Network











Remote IO

Chassis 2

Remote IORemote IO

Chassis 2Chassis 2

Remote IO

Chassis 3

Remote IORemote IO

Chassis 3Chassis 3


Remote IOChassis 4




Remote IOChassis 5



DH+ Addr 17Channel 1A

Allen-BradleyPLC5/40

Processor

RIO Chassis 1Channel 1B

DH+ Addr 17DH+ Addr 17Channel 1AChannel 1A

AllenAllen--BradleyBradleyPLC5/40PLC5/40

ProcessorProcessor

RIO Chassis 1RIO Chassis 1Channel 1BChannel 1B

DH+ Network

Remote IO Network


CO2 Monitoring and Control System: Sam Adams Brewery, Cincinnati, OH

Htec Systems, Inc. was retained by a regional brewery to design,

fabricate, install and commission a CO2 Monitoring and Control

System for the plant in Cincinnati, OH. The plant had purchased an

instrument to monitor the CO2 levels in the cellars but the accuracy

was suspect and the alarm was activated constantly. The objectives

of Htec Systems were to provide accurate measurements and

maintain CO2 levels in the cellars below the OSHA Permissible

Exposure Limit (PEL).

Htec Systems visited the site to obtain field data with regard layout of

the cellars with regard to locations of tanks, piping, drains, walkways,

windows and doors. Detailed engineering drawings were prepared

and submitted to the company for approval.

A control panel was constructed to continuously sample ten locations

in the cellars for CO2 levels. The CO2 concentrations were

sequentially analyzed with an industrial grade monitor with the levels

graphically presented on a monitor mounted on the front door of the

panel. If the CO2 levels exceed the OSHA PEL, exhaust fans were

actuated, venting the gas outside until the levels were reduced.

The CO2 Monitoring and Control System was controlled with an

Allen-Bradley CompactLogix PLC. The 8-Hour OSHA PEL Time

Weighted Average was continuously graphically presented.


AK SteelConfined Space Entry Permit Database (CSEP)

Middletown, OH

Htec developed the CSEP database, a report generation database that creates a Confined Space Permit report in 5 sections: Confined Space Permit and information for the Safety Stand-By, Rescue Team, Entrant and Supervisor personnel.

The CSEP software has been in use for more than 10 years by over 50 managers throughout the plant.

Additional Projects

Quarterly Indoor Air Quality Testing CertificationCincinnati Children’s Hospital Medical Center

Cincinnati, OH

Htec’s sister company, Hayden Safety Engineers, conducts quarterly indoor quality air quality monitoring of the operating rooms on the Third Floor and bone marrow transplant rooms on the Fifth Floor of CCHMC. The testing is conducted for one hour in each clean unoccupied room to measure and certify levels of airborne particles, mold spores and bacteria. Twenty minutes of outdoor sampling is also conducted for comparison purposes and to enable calculation of the HVAC Particle Removal Percentages. The hospital receives a detailed report including Summary Tables, Graphs, and Analytical Results following each monitoring session.


Control Systems Integration

Control Systems Integration is becoming increasingly critical for any industrial facility to operate effectively. Data must quickly move from the factory floor process to the operator to the supervisor’s office.

To be able to integrate, a facility needs standards for Programmable Logic Controllers (PLC) and industrial controls, Human-Machine Interfaces (HMI) and data storage software and a plant network. Without these standards, integration is difficult.

Integration is not only about PLCs and software – a solid understanding of the process is necessary for quality control system implementation. Htec is a multi-disciplinary team of engineers with mechanical, chemical, electrical, environmental, microbiological and safety experience.

Newly installed systems should adhere to the standards while older, existing systems may need to be upgraded or at least modified to provide key process data.

To assist you with systems integration, Htec Systems offers the following services:

PLC Design/Programming: Allen-Bradley MicroLogix, SLC, CompactLogix, ControlLogix, PLC-5; Siemens S7-300

Low Voltage Electrical Power Design (i.e. Motor Control Centers, NEMA, IEC)

HMI Design (Wonderware, RSView ME, RSView32, WinCC, Panelbuilder32)

Control Panel Design and Fabrication (UL508a)

Datalogging and Retrieval (SQL, Access, Excel, Rockwell, OPC)

Electrical/Control System Redesigns

Before AfterHuman Machine Interfaces (HMI) PLC Motor Control Power Distribution


HMI Examples: Wonderware


HMI Examples: FactoryTalk (RSView) ME


HMI Examples: WinCC (English & Romanian Text)


Christopher S. Hayden

Chris Hayden and the Romanian Operators and

Maintenance Staff (9/2009)

Chris Hayden Project Profiles 12 2011

Documents

usa htec systems

romania htec systems

wastewater treatment

wwtp equipment

wastewater ph control

new wwtp

equipment installation

plant locations