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more attention to that area on the wastewater side. Nutrient reduction is a huge issue for wastewater treatment plants, and one alternative to costly plant upgrades is to remove those nutrients (mainly nitrogen and phosphorus) from the lakes and streams by other means, such as progressive farming practices and erosion control. Now it appears the drinking water side is turning in a similar direction. That can only be a good thing. After all, water doesnt obey political boundaries like city limits and county lines. It obeys gravity; thats how we get watersheds. Learning to approach water quality on a watershed basis requires new ways of thinking.
And on the subject of thinking, the Brazos River Authority in Texas has new thoughts on how to educate citizens about the importance of water quality and conservation (see Winning Them Over in this issue). We see lots of water agencies sponsoring education programs for children, and of course theyre great. The Brazos authoritys online Water School caters to adults. This turns on its head the conventional idea (a sound one, by the way) that habits form early and we need to teach good behaviors to members of the next generation who may then inuence their parents. An adult-oriented approach reaches the people who make the water usage and water infrastructure spending decisions today and in the bargain are in a pretty good place from which to inuence kids. If were going to ght that battle of public education, it makes sense to fight it on both these fronts. So heres a hat tip to the Brazos River Authority. We hope you enjoy this and future monthly issues of WSO. wso
wsomag.com January 2013
ators run the water plant and two run the wastewater plant during normal business hours. After hours, one operator monitors both treatment plants with the SCADA system. Water plant operators report to Evans, who sets performance goals. They make production-change, lter-backwashing and disinfection-doserate decisions, make all process control adjustments and checks, and handle customer service calls after hours. Evans, who reports to superintendent of operations Bob Bandarra, holds The UFRVs are typically 6,000 gallons per square foot during winter Class 4 water treatment plant and water and 3,000 during summer. In the summer of 2009, the UFRVs decreased distribution licenses and has been with to 900 gallons per square foot for several days. the city for 33 years. His team includes lead operator Karl Lowry (Class 3, 19 BILL EVANS years) and operators Gary Hess (Class 3, 41 years), Randy Osborn (Class 3, 38 years), Gary Gillen (Class 4, 33 October, and returned to normal levels when the cooler fall weather reduced years), Sally Pytel (Class 3, 12 years), Keith Fredrickson (Class 3, 9 years), algae growth, Evans recalls. Since then, the plant has gone through sevand Shayla Frances (Class 3, 7 years). eral upgrades to help the situation: New 75 hp vertical pump motors (U.S. Motors/Nidec Motor CorpoWell-trained ration) for redundancy, and new electrical service equipment, Training the operators on both the water and wastewater facilities gives including an automatic transfer switch to reduce outage risks. them a broad background, says Evans. They know both systems well, Air scour system (HSI blower and AWI underdrains) to reduce and even though it takes longer to train them, it makes them much more backwash water use. knowledgeable. The operators appreciate the variety of work at the two plants, New motor control cabinet (Allen-Bradley/Rockwell Automation) and cross-training allows more exibility when operators take vacation. and plant main switchgear (Schneider Electric) to update the elecThe plant team conducts annual tours for groups, including Western trical system and reduce failure risk. Washington University water-quality classes and Bellingham elementary New 1,000 kW emergency generator (Baldor). school students. It used to be part of the fth grade curriculum, says Peg Wendling, laboratory supervisor for the Bellingham plants. They Many tasks still use a video series on water resources and treatment that the city The Bellingham plants seven operators are responsible for water and developed 10 years ago. Bill Evans is featured prominently in that series wastewater operations, including monitoring and operation of 14 storage as Bill Y the Water Guy. reservoirs (29 million gallons of storage) and 14 pump stations. Two operwsomag.com January 2013
When Evans asked the power company to check to see if power was even coming into the plant, power plant staff found and repaired a loose wire that had caused the outage. The power was out for an hour, causing us to lose an estimated 2.3 million gallons of water in our gravity reservoir, says Evans. During the height of the algae problem, lter backwashing used about two million gallons of water per day. Operators optimized the amount of treated water used to clean the lters, and adjusted raw water screen wash times to reduce raw water turbidity, which was above 1.0 NTU, rather than the usual 0.45 NTU. The operators also increased chemical coagulation doses to maintain treated water quality. Even with the water use restrictions, operators had to backwash more often than normal. The frequent backwash issue lasted from July through
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Successful career
Woodard & Curran began working with the city as the new plant was being phased in. The old plant across the street, built in the 1930s, continued to operate until the changeover was complete in 2007. Geary was assigned to operate the old plant, while the operators were trained on the new facility. The new plant represented a big step forward in technology for the city, and ultimately the city hired Woodard & Curran to operate it. Geary became the lead operator. Its the latest job in a 23-year career that Geary calls both secure and satisfying. I started out pursuing a degree in business administration, he says. But my sister was working in a water treatment laboratory, and she got me interested in water and wastewater. He took courses at University of Massachusetts Lowell, passed the state licensing exams, and got a job at the Lynn Water Treatment Plant (in his hometown), working for a contract operator. Excelling in his role, Geary was assigned to manage the startup of a treatment plant in North Adams, Mass., and later be the manager of utilities at Salem, N.H., before joining Woodard & Curran 11 years ago. He holds both Class 4T (treatment) and Class 3D (distribution) certications for Massachusetts and New Hampshire. Ive learned a lot through experience and through studying on my own, he says. Over the last couple of years, Ive been trying to learn more about SCADA controls and electronics. I have people who know it like the back of their hands, but you really need to understand more about it when youre working with them. The Lawrence assignment has put his qualications, and those of his six staff members, to the test. We have a lot of new bells and whistles here, he says. Plus, the state regulatory authorities handed down a list of some 170 consent order items that the new plant had to address when Woodard & Curran took over.
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Lots of interaction
People often dont think about where their water comes from or how it gets there until they have a problem, says Pierce. The Water School is built on a framework of blogging software, allowing the team to treat each individual question as a separate entry with its own box. The format also allows readers to pose follow-up questions on topics that pique their curiosity. Since funding for the project was limited it began with no budget Pierce and her team had to be creative. We used our in-house information technology resources to help us develop the site, she says. And we used freeware we found to develop the actual pages. The questions were compiled by public information staff members, who researched and wrote the answers, but her team often sent questions and answers to staff engineers and hydrologists to conrm the information they were preparing to share. It was pretty much a six-month project of collecting the questions, rening the answers, and then getting the material vetted and approved, says Pierce. It was a learning process. We have an incredibly educated staff that has helped educate our department so we can answer the publics questions. The team focused on keeping the answers understandable for the average reader. It may be a little eleIllustrations on the online Water School, mentary for some adults, but such as the basic water cycle, help visually explain topics. for the most part it is geared
to people 14 or 15 and up, Pierce says. The authority uses the Major Ri vers program developed with other Texas authorities to educate younger students about water issues, but the Water School is focused on junior high students and up.
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pulsator system pilot study and performed tests on incoming and nished water samples with laboratory analysts from Inlco Degremont. Says Skinner, Because the operators learned quickly, this was the rst location for an Inlco pilot study that successfully used and educated plant personnel in operating a pilot plant without the need for constant on-site Inlco staff. Besides the Superpulsator system, plant equipment includes: Ferric chloride, caustic soda, uoride and orthophosphate chemical feed pumps (Watson-Marlow) PolyBlend chemical feed pumps (Siemens Water Technologies) Liquid chemical transfer pumps (Iwaki - Walchem) Chlorine feed system (Siemens Water Technologies) Powdered activated carbon dry chemical feed (MERRICK Industries) In-line InstoMixers (Walker Process Equipment) Lightnin Rapid Mixers (SPX Flow Technology) Dual-media lters and lter underdrain system (Leopold a Xylem Brand) Electric operating valves and rate-of-ow control valves (Rotork) PLC SCADA system (Allen-Bradley/Rockwell Automation) Computer-controlled plant operating system (Rockwell Automation) Flowmeters (Yokogawa) Continuous pH, chlorine, uoride and turbidity meters (Hach) Since space was limited, MWH recommended Superpulsator technology (Inlco Degremont), which combines occulation and coagulation in a single tank. There is no need for additional sludge collection and removal facilities, and there are few moving parts. The existing settling tanks were converted to a residual holding tank, and the existing backwash wastewater holding tank was converted to the backwash water tank. The Superpulsator unit is an upow system that combines sludgeblanket occulation with inclined plate settling. Chemically dosed raw water enters a high-rate occulation tank, then ows by gravity to a sealed vacuum chamber that discharges the water to laterals at the bottom of the reactor. A pump creates a vacuum in the chamber, causing the water level to rise to a predetermined height. A timer actuates an inlet valve on the chamber to open quickly so that the water stored in the chamber drains rapidly into the bottom of the distribution system. This discharge creates a pulsating action, while the sludge blanket expands in the reactor. As the water moves upward in the reactor, it starts to occulate. A system of parallel plates inclined at 60 degrees enhances clarication. The upper level of the sludge blanket is controlled by overow into a sludge concentrator, where the excess sludge is thickened before discharge. Above the inclined plates, the claried water is collected through a set of submerged laterals.
Transition challenges
At the startup of the new plant, some operators were excited, while others were intimidated by the computer-controlled technology, Skinner recalls. The old lime softening plant used computer entries only for state reports and records; every operation was a hands-on control system. Operators walked from room to room and building to building to operate the plant and maintain levels in four water distribution systems. With the new system, operators were worried that a wrong click of the computer mouse would hurt water quality or create an overow somewhere. One plant operator never owned a computer and had to learn all the basics before operating the new plant. It was very difcult for this operator to download all this new information at once, recalls Skinner. The staff pitched in a little extra every day to work with him. He got up to speed with reassurance that the rest of the staff would help out when needed. Four to six weeks before startup, equipment vendors conducted classroom and hands-on training for the chemical pumps, powdered activated carbon, ow valves and controllers. They covered ow rate adjustment and chemical mixture preparation. Two weeks of vendor training on the SCADA system helped transition the operators over to computer command and live continuous data feedback, says Skinner. Training also included identifying and applying the individual PLC module components. Operators relied heavily on the O&M manual.
To the test
The operators and laboratory technician were involved with the Super-
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the polymer diaphragm pumps experience reduced audible stroke knocking. Operators must take the pump apart, extract the hardened compressed polymer from the chamber, and check the balls, springs and efuent line before re-assembling the pump and placing it back into service. Operator Michael Boone found a very small chlorine leak caused by a nearly invisible crack in the combined lter efuent chlorine line in an outdoor vault. The efcient operation of any water plant requires the operators to have good sensory perception, says Skinner.
Always improving
The operators better themselves by advancing to the next license grade. Theyre constantly learning and looking at new ways of doing things and nding better methods for running the plant, says Skinner. They have completed the basic water and advanced water courses offered by the Operator Training Committee of Ohio (OTCO). They also take the Sacramento State University operator training correspondence courses on different water treatment topics. This is much more effective than seminars, since they are exposed to so much more information, says Skinner. In April 2008, eight months after startup, the plant team conducted a full-scale study with the Superpulsator clarier and a lter to see if they could high-rate the system. This was successful, and we were upgraded to a 7.5 mgd plant with a 6.0 mgd operating capacity, without having to build another Superpulsator or lter, says Skinner. In 2010, the plant upgraded to a second communication system, along with a new river pump station and transmission lines and four new distribution tanks. Right now, were considering another full-scale Superpulsator study to see if we can push our current plant production even higher to accommodate more water customers, says Skinner. If not, we have room to add an additional Superpulsator unit to meet future demand. With the current economy and limited infrastructure funding, that remains to be seen. Were experiencing the funding squeeze every water system currently feels to operate and maintain their systems, says Skinner. Nevertheless, the plant is solidly on course for a long life producing high-quality water for Steubenville and its surroundings. wso
Rocky Zinno, left, and Bill Skinner under the lter building in the pipe galley.
The new plants peristaltic chemical pumps are more accurate and reliable than the old high-maintenance volumetric and gravimetric dry chemical feeders. And, the Superpulsator clariers operate themselves, says Skinner. The Allen-Bradley controller adjusts the vent valve timing to control the volume and timing of the pulsing, and it also controls excess sludge removal. There are reliable vacuum pumps that run 24 hours a day to supply the lift in the vacuum chamber.
MORE INFO:
Hach Company
800/227-4224 www.hach.com
Easier on operators
New technology has made operators lives easier. With the old plant, they had to manually adjust the chemical volume on every chemical feeder every time the water ow through the plant changed, says Skinner. With the SCADA, the ow pace automatically adjusts every chemical feed throughout the plant. The coagulant we use is 41 percent ferric chloride, but because we receive it in liquid form, a certain delivery might be 41.7 or 40.7. We can enter the exact gure in the SCADA, and this helps control the chemical application. Operators have become accustomed to the sights, smells and sounds of the new equipment. They use their ears as much as the eyes or nose, since we have noises we didnt have before, says Skinner. We have an air-operated valve with a compressor and vacuum pumps that run all the time, so you get used to hearing the vacuum chamber release and the swish of air. You still have to use your senses and not just look at a computer screen all day. This came in handy recently when operators heard air leaking from an air-operated solenoid valve that needed to be replaced. Occasionally,
800/446-1151 www.degremont-technologies.com
Walchem
508/429-1110 www.walchem.com
MWH Global
303/533-1900brand www.mwhglobal.com
Rockwell Automation
414/382-2000 www.rockwellautomation.com/industries/water
Rotork
585/247-2304 www.rotork.com
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Graph 1
Graph 2
Full-scale performance
In November 2008, the district commissioned a new treatment plant designed by Carollo Engineers that uses GAC contactors primarily to reduce TTHM in the distribution system. The plant allows operators to blend State Water Project surface water and local surface water. It also allows them to bypass the system when appropriate, providing great exibility to meet water-quality standards. Since startup, the entire ltered efuent production has been pumped through the GAC contactors. Graph 1 shows the average TTHM levels within the distribution system from January 2008 to February 2010. From January to October 2008, the average monthly TTHM was 54 g/L. From January to October 2009, the average was 29 g/L. The average TTHM from November 2008 to February 2010 was 28 g/L. This meant GAC reduced TTHMs in the distribution system by 47 percent. Table 1 shows the systems running annual averages for TTHMs from 2002 to 2010. This improvement came despite a shift toward using more surface water: The system used 61 percent surface water in 2008 and 65 percent in 2009. This shift would tend to increase TTHMs, but in actuality, TTHM levels did not increase.
The GAC treatment also dealt effectively with a 17 percent increase in bromide in the raw water, from 230 g/L for January through October 2008 to 270 g/L for November 2008 through February 2010. With the GAC contactors online, the increase in TTHM that would otherwise be expected with higher bromides did not occur.
Cost analysis
Postltration GAC contactors have proven highly effective in reducing TOC. The remaining issue for the Palmdale district is balancing the cost of treatment with achieving water-quality goals. The district has tried to create a rule of thumb that may help other utilities considering GAC. Looking at 26 months of operation using GAC contactors, the district calculated the cost per acrefoot of water treated at the current market price of GAC (Table 2). The primary cost of GAC treatment has been the purchase of GAC media. Here is how Table 2 operational changes in the district have affected the cost of treatment: Coagulation. The addition of GAC for TOC removal means there is more exibility in dosing primary coagulant: The district no longer must achieve high levels of TOC removal in the coagulation and sedimentation process. Instead, the staff can dose its primary coagulant strictly for turbidity removal, reducing dosage and lowering chemical costs. Taste and odor control. Before GAC treatment, the district used powdered activated carbon (PAC) to reduce taste and odor issues related to algal blooms. Now PAC is no longer needed, and that reduces treatment cost by $4 to $7 per acre-foot. Boosting. Filtered water now must be boosted to the GAC contactors adding to overall power consumption, but that cost seems to be offset by lower chemical costs. GAC media usage. The district believes it can comply with Stage 2 DBPR with four to ve change-outs of the eight contactors each year, costing $80 to $100 per acre-foot if fresh GAC is used. If custom reactivated GAC performs as well, the cost could be reduced to $60 to $75 per acre-foot. Reactivation also eliminates cost and long-term liability related to disposal. Custom reactivation also has an environmental bene(Continued on page 29)
wsomag.com January 2013
TOCs improved
Graph 2 shows raw water and plant efuent TOC from January 2008 through February 2010 and shows the sequencing of the GAC contactors. When a new contactor came online, the prior contactors remained in service. The average TOC from January to October 2008, before GAC treatment, was 2.6 mg/L raw and 1.5 mg/L efuent, for an average reduction of 42 percent. From January to October 2009 with GAC treatment online, the average TOC was 2.2 mg/L raw and 0.8 mg/L efuent, for an average reduction of 64 percent. The average TOC since introduction of GAC, from November 2008 to February 2010, was 2.3 mg/L raw and 0.7 mg/L efuent, for an average reduction of 70 percent. This shows that GAC treatment improved TOC reduction by 22 percentage points.
Table 1
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PRODUCT FOCUS:
BY MIKE SCHOBLASKA
Membrane system
The Aqua UltraFiltration membrane system from Aqua-Aerobic Systems offers a compact T-rack design, zerobreak bers and no air scouring. The multibore bers are made of polyethersulphone (PES) with seven capillaries per ber for strength. The alternating top and bottom feed and inside-out ltration ow provides uniform ltrate and backwash ows to minimize plugging, chemical usage and cleaning frequency. The membranes can be cleaned at a higher pH with caustic instead of chlorine. Smaller, uniform pores provide 6-log removal for bacteria and 4-log removal for viruses. The systems are suited to drinking water, reverse osmosis pre-treatment, industrial water treatment, tertiary wastewater treatment, and reuse applications. 800/940-5008; www.aqua-aerobic.com.
Screen lter
A self-cleaning screen filter from Forsta Filters uses system pressure to clean itself. A rigid cylinder screen strains particles, trapping debris on the inside. The buildup causes differential pressure across the inlet and outlet. A controller monitors the lter and opens a ush valve when it senses adequate pressure. This creates rapid ow through the internal cleaning apparatus, which vacuums buildup from the screen and expels it. The backwash cycle does not require the entire system ow to stop and reverse. Instead, a point-of-suction backwash reverses ow across the screen only directly in front of suction nozzles. This allows the cleaning mechanism to scan and clean the screen incrementally without disrupting the main ow through the lter. Single units accommodate ow rates up to 8,000 gpm. 888/936-7782; www.forstalters.com.
Laser nephelometer
The FilterTrak 660sc from Hach ensures that small changes in turbidity measurements accurately represent real turbidity events by detecting turbidity changes as low as 0.0003 NTU. Operators can detect impending lter breakthrough, delineate lter ripening, and maximize effective lter run time. Using advanced laser optics and signal processing, the instrument detects submicron particles that are often precursors to larger particles. 800/227-4224; www.hach.com.
Measuring principle
The spectro::lyser measuring principle from s::can Measuring Systems measures UV and visible spectrum radiation (UV-Vis). It quanties changes in TOC or COD, helps identify several differentiated groups of organics, and can detect individual organic substances. It can distinguish between normal and abnormal organic composition using event detection systems, allowing treatment plants to create spectral ngerprints of incoming water. 888/694-3230; www.s-can.us.
Current meter
The Streaming Current Meter (SCM) from IN USA helps water treatment facilities control water quality by measuring and regulating continuous online coagulant dosage. The meter measures the charge on suspended particles. It is suited for measuring and controlling coagulant dosage in occulation systems. It minimizes jar testing and zeta potential measurement in the lab and saves coagulant usage. 781/4442829; www.inusacorp.com.
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NEWS
Badger Meter donates to Water Buffalos group
Badger Meter donated $5,000 to the Water Buffalos in support of their efforts to construct and maintain safe, reliable drinking water systems in developing countries. The Water Buffalos include more than 40 members from the global water and wastewater industry who share a passion for motorcycles and the belief that everyone deserves access to clean drinking water. Cindy Kransler, director of utility sales at Badger Meter, and Rob Fehl, product marketing manager, have been involved with the fundraising group.
INDUSTRY
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