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Welcome. Answers for Industry The Orlando Story: Leveraging Operating Cost Reduction and Improving Water Quality Gene E. Keyser October 21, 2009.

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  1. Welcome

  2. Answers for IndustryThe Orlando Story: Leveraging Operating Cost Reduction and Improving Water QualityGene E. KeyserOctober 21, 2009

  3. 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. About Gene Keyser

  4. 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

  5. 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

  6. The Orlando StoryThe Base Case – Split Plant Bardenpho Process 12 mgd Rated at 20 mgd Completed 1993

  7. The Orlando StoryThe Base Case – Split Plant Rotating Biological Contact Primary Clarification then 2 stages with methanol addition Alum Addition for Phosphorus control 16 mgd Rated at 36 mgd Completed 1980

  8. The Orlando StoryChemicals 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

  9. 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

  10. The Orlando StoryThe 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

  11. 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

  12. 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

  13. 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)

  14. The Orlando StoryThe Six Sigma Approach to Wastewater • 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

  15. 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.

  16. LSL USL The Orlando StoryData, Data, and More Data • Wastewater • Assume nothing • Chase any sustainable or reproducible positive event. • Track down every exception, good or bad.

  17. Chemscan Serial Number 2 Ammonia Nitrite Nitrate o-Phosphate Each Stage and Effluent x 4 Play with one against the other The Orlando Story“Pilot” Work – Full Scale Ahead

  18. The Orlando Story“Pilot” Work – Full Scale Ahead

  19. 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 StoryPermit, Process, and Projects

  20. The Orlando StoryProjects

  21. The Orlando StoryProjects • Replaced anaerobic digesters with lime stabilization and NO digestion.

  22. The Orlando Story“Pilot” Work – Full Scale Ahead

  23. LSL USL The Orlando StoryData, Data, and More Data • Wastewater • Assume nothing • Chase any sustainable or reproducible positive event on rate of treatment. • Track down every exception, good or bad.

  24. The Orlando StoryTRAIN Wreck • Mechanical versus Automated Control • NOT GOOD – Metering post process, daily control

  25. 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 StoryOperations’ Revolt: Round 1

  26. Accidents DO HAPPEN! The Orlando StoryProcess Optimization

  27. 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 StoryTHE Permit

  28. The Orlando StoryData, Data, and More Data

  29. The Orlando StoryReal Data, Full Scale, Real Time

  30. Data Overload Crash & Burn WinCC Replaces WonderWare Data Integrity Update, Upgrade Compatibility $$$, It’s always the money The Orlando StoryOperations’ Revolt : Round 2

  31. Distributed Control System Redundant Ring & Star Fiber 17 PLC’s 55,000 tags ~0.6 GB daily The Orlando StoryEveryone, Everything on Board

  32. 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 The Orlando StoryEveryone, Everything on Board

  33. … 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 StoryEveryone, Everything on Board

  34. 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 Story… then the light went out

  35. 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 The Orlando StoryThe Problem

  36. 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 Medium Voltage Switchgear and Distribution Replacement

  37. 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! Medium Voltage Switchgear and Distribution Replacement

  38. The Orlando Storyrob 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

  39. The Orlando Storyrob 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.

  40. Medium Voltage Switchgear and Distribution Replacement What’s Missing?

  41. Medium Voltage Switchgear and Distribution Replacement What’s Missing? (besides the coffee)

  42. The Orlando StoryReal Power – Sleep at Last • What’s Missing? • Wires • Mechanical relays • Indicator Lights • Buttons • Switches • Active or passive filters for harmonics • REPLACED by use of Profibus DP technology

  43. Medium Voltage Switchgear and Distribution Replacement • Installed 2005/2006 – US$ 7.2 MM

  44. 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 StorySelling Effluent at a Profit

  45. 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 StoryNew Concrete

  46. 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 StoryNext?

  47. The Orlando Story • Acknowledgements • Alan Oyler • Guy Mecabe • M. Hester • E. Ray • B. Smith • C. Thompson • G. Vasquez • W. Wood

  48. Questions?

  49. Thank you for attending! • Gene E. Keyser • Key Solutions, Inc. • www.key-solutions-inc.com • (904) 635-5151 • doc@key-solutions-inc.com

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