Copyright © Siemens AG 2009 - All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior.

Copyright © Siemens AG 2009 - All rights reservedNo portion of this document may be reproduced either mechanically or electronically without the prior consent of Siemens.

Welcome

Copyright © Siemens AG 2009 - All rights reservedNo portion of this document may be reproduced either mechanically

or electronically without the prior consent of Siemens.

Answers for Industry

The Orlando Story: Leveraging Operating Cost Reduction and Improving Water Quality

Gene E. KeyserOctober 21, 2009

Page 3 Copyright © Key Solutions, Inc. 2009 - All rights reservedNo portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions.

About Gene Keyser

More than 30 years experience in chemical and biochemical processing including 19 years in water and wastewater systems process, process control, and electrical design. He has been responsible for all phases of projects from process conception through system commissioning.

Education:Ph.D. in Organic Chemistry, University of Illinois, 1979; B.S. in Chemistry, Duke University, 1975.


The Orlando Story

The Base Case – Split Plant The Plan Data, Data, and More Data “Pilot” Work – Full Scale Ahead Permit, Process, and Projects Train Wreck The Permit Real Data, Full Scale, Real Time Everyone, Everything on Board … then the light went out Real Power – Sleep at Last Selling Effluent at a Profit New Concrete


The Orlando StoryThe Base Case – Split Plant

Operations circa 1992 – ‘98: Flow at 28 – 30 mgd; I&I: 90 – 100+ mgd during wet weather Loading

135 mg/L cBOD; 245 mg/L TSS; 47 mg/L TKN; 8 mg/L Total Phosphorus 150 mg/L Total Alkalinity

Permit Status: 5 cBOD; 5 TSS; 3 Total Nitrogen; 0.78 Total Phosphorus 40 mgd

Notices of Violation monthly or more often Total Nitrogen Total Phosphorus



Bardenpho Process

12 mgd

Rated at 20 mgd

Completed 1993



Rotating Biological Contact

Primary Clarification then 2 stages with methanol addition

Alum Addition for Phosphorus control

16 mgd

Rated at 36 mgd

Completed 1980


The Orlando Story Chemicals and more Chemicals

Rotating Biological Contact Facility

5,000 gpd Alum (50% solution)

4,000 gpd methanol for denitrification

Bardenpho Process

~1 – 2,000 gpd Alum

Chlorine Gas Injection

~2000 ppd disinfection

~5500 ppd breakpoint chlorination for ammonia removal

Sulfur Dioxide Gas Injection for dechlorination


The Orlando StoryMaintenance Everywhere

53 on site staff (35 operations, 18 maintenance)

$1.78 per thousand gallons cost to produce effluent (not including collection system)

Near highest sewer rates in region at $1.80 per thousand

FL-DEP permit at risk for lack of compliance

Expansion of Bardenpho to replace RBC budgeted at $102 MM

Unbudgeted repair of Anaerobic Digesters contemplated at $30+ MM


The Orlando Story The Problem … No good plan

FL – DEP requirement and public mandate for reclaim supply

Upside-down rates or unpopular rate increase

Landlocked asset base – few connection fees through growth

… And still no reclaim


The Orlando StoryTHE PLAN

Identify Plant Problems

Repair, Patch, Correct, ANY port in a storm

18 operations, 35 maintenance (net zero head count reduction)

Repair Collection system to STOP Inflow & Infiltration

Maximize Bardenpho Trains

Shut Down RBC

Upgrade pinch points


The Orlando StoryNo Air, No Power, and …

The Problem Identified

Alum addition precipitated not only aluminum phosphate but also calcium sulfate which became hydrogen sulfide in digestion which destroyed digester train.

Press filtrate at 150 kgpd

800+ mg/L TKN 1,000 ppd v. 11,750 ppd influent

1,500 mg/L TP 1875 ppd v. 2,000 ppd influent

Alum (iron was worse) inhibition of BNR process by alkalinity reduction


The Orlando StoryNo Data, No Voice

Bardenpho Process 4 each 5.1 mg trains, 4 – 6 mgd each original design cBOD limited (influent 2.6:1 cBOD:TKN; 5.2:1 COD:TKN Alum inhibited (alkalinity)


The Orlando StoryThe Six Sigma Approach to Wastewater

0.13%2.14% 13.60%

34.13% 34.13%

13.60% 2.14%0.13%

-3S -2S -1S 0 +1S +2S +3S

68.26%

95.46%

99.73%

Chemical Processing Specify, Confirm, and Control Raw materials Confirm and Control each step of production Achieve 99.9999% predictability Less than 1 failure per million events 6σ


The Orlando StoryThe Six Sigma Approach to Wastewater

Wastewater

Oops, unknown, uncontrolled raw material.

How then 6σ?

Monitor and measure nutrients as soon as practical.

Control and measure each unit process in real time.


The Orlando StoryData, Data, and More Data

Wastewater

Assume nothing

Chase any sustainable or reproducible positive event.

Track down every exception, good or bad.LSL USL


The Orlando Story“Pilot” Work – Full Scale Ahead

Chemscan Serial Number 2 Ammonia Nitrite Nitrate o-Phosphate

Each Stage and Effluent x 4

Play with one against the other




The Orlando Story Permit, Process, and Projects

With I&I “fixed” and flows to 18 mgd Anaerobic Filtrate to RBC plant All flow to Bardenpho ~$1.23 per thousand gallons Add AIR to Bardenpho (but where?)


The Orlando Story Projects


The Orlando Story Projects

Replaced anaerobic digesters with lime stabilization and NO digestion.





Wastewater

Assume nothing

Chase any sustainable or reproducible positive event on rate of treatment.

Track down every exception, good or bad.LSL USL


The Orlando StoryTRAIN Wreck

Mechanical versus Automated Control NOT GOOD – Metering post process, daily control

50%

60%

70%

80%

90%

100%

110%

120%

130%

140%

6/23 6/25 6/27 6/29 7/1 7/3 7/5

Fra

cti

on

of

Av

era

ge D

aily

Flo

w

EastTrain

WestTrain


The Orlando Story Operations’ Revolt: Round 1

Manual Tracking and Graphics

AS 400 replaced with S7-300 series PLC for ½ of

Bardenpho Process

WonderWare to the rescue

Data Integrity? Timing? Control?


The Orlando Story Process Optimization

Accidents DO HAPPEN!


The Orlando Story THE Permit

Target monthly limit on daily basis

>>> Target 1 violation per three years

Monitor , Control, Treat

40 mgd AADF Max Month 48 mgd Peak Hour 60 mgd

$1.25 per thousand




The Orlando Story Real Data, Full Scale, Real Time


The Orlando Story Operations’ Revolt : Round 2

Data Overload Crash & Burn

WinCC Replaces

WonderWare Data Integrity Update, Upgrade Compatibility

$$$, It’s always the money


The Orlando Story Everyone, Everything on Board

Distributed Control System Redundant Ring & Star Fiber 17 PLC’s 55,000 tags ~0.6 GB daily



Rebuild Master Pump Station Implement Equalization Test and Select Clarifier Mechanism Test and Add Filtration Capacity “Forever” Construction Still on “temporary blowers” Overtime reduced from ~20,000 hrs. annually to <100

4,000 hrs. OT on instrumentation alone

~$1.00 per thousand



… and still no Reclaim NPW Demand – 28 mile pipeline Estimated 3 MW pumping capacity

Circa 2000 – 2004 350 power outages annually >> 1 min >2 “flickers” per day per MCC (17 of them) Aluminum 480V and 12.47 kV on site MV/LV Distribution installed 1968 – 1988 Power Factor <0.6, THD >25-40% Demand 6 x average


The Orlando Story … then the light went out

Reproducibly,

failed lighting ballasts shut down 12.47 kV !!!

4 independent generator systems, 7 generators

4.4 MW capacity + 6.5 MW demand = uh-oh

And they wanted more power


The Orlando StoryThe Problem

3 bid projects: 1995 - 2001 –$ 9-15 MM New LV distribution New ATS’s Open Transition Only Separate Power Control System

No harmonics mitigation 2 additional generators No new MV distribution No new MCC’s No new transformers


Medium Voltage Switchgear and Distribution Replacement

9.6 MW with new dual radial distribution 3 New MTU 3.2 MW generators

MTBF design basis Eliminate ALL copper interlocks Eliminate ALL local controls Dual feed MCC’s radially from MV switchgear Harmonics mitigation Δ-Δ transformers for unchanged phase angle Δ-Υ transformers for 30° rotation of phase angle

Increased efficiency Increased MTBF



TIA + TIP = TIF

Power delivery coordinated by automation Distributed Controls Siprotec Protective Relays

CLEAN power without added equipment!

$7.0 MM estimated

Order the generators!


The Orlando Story rob Peter to pay Paul

60 mgd Reclaim Storage and Pump Station

Two separately fed busses

Five 700 hp VFD drives, plus

Five 150 hp VFD drives.

OR


The Orlando Story rob Peter to pay Paul

Use one 700 hp VFD with RVSS backup and one 150 hp VFD with RVSS backup and synchronized, (closed transition), across the line contactors.



What’s Missing?



What’s Missing? (besides the coffee)


The Orlando StoryReal Power – Sleep at Last

What’s Missing?WiresMechanical relays Indicator LightsButtonsSwitchesActive or passive filters for harmonics

REPLACED by use of Profibus DP technology



Installed 2005/2006 – US$ 7.2 MM


The Orlando Story Selling Effluent at a Profit

Cost:

$ 0.87 per thousand gallons treated Sales Price:

$1.20 per thousand gallons treated

7 x $0.60 x 23,000 x 365 = $35.2 MM

The difference between simply elegant and elegantly simple is profit. GEK


The Orlando Story New Concrete

Permanent Solutions for 48 to 60 mgd New Blowers and Blower Building New Clarifier Mechanisms Fine Bubble Diffused Aeration Serpentine Stages New LV MCC’s Interruptible Power Supply Agreement

Target: $0.72 per thousand


The Orlando Story Next?

Collection System Management 100% Redundancy Beyond Class 1 Reliability Hydraulic & Operating Cost Optimization

Solids Disposition

The next generation: Northeast Polk County WWRF Power by Siemens


The Orlando Story

Acknowledgements

Alan OylerGuy Mecabe

M. HesterE. Ray

B. SmithC. ThompsonG. Vasquez

W. Wood

Copyright © Siemens AG 2009 - All rights reservedNo portion of this document may be reproduced either mechanically or electronically without the prior consent of Siemens.

Questions?

Page 49 Copyright © Siemens AG 2009 - All rights reservedNo portion of this document may be reproduced either mechanically or electronically without the prior consent of Siemens.

Thank you for attending!

Gene E. KeyserKey Solutions, Inc.www.key-solutions-inc.com

(904) [email protected]

Copyright © Siemens AG 2009 - All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior.

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