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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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Presentation on theme: "Copyright © Siemens AG 2009 - All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior."— Presentation transcript:

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

2 Copyright © Siemens AG All rights reserved No 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. Keyser October 21, 2009

3 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 3 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.

4 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 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 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 5 The Orlando Story The 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 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 6 The Orlando Story The Base Case – Split Plant Bardenpho Process 12 mgd Rated at 20 mgd Completed 1993

7 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 7 The Orlando Story The 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 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 8 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

9 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 9 The Orlando Story Maintenance 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 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 10 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

11 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 11 The Orlando Story THE 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 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 12 The Orlando Story No 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 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 13 The Orlando Story No 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 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 14 The Orlando Story The Six Sigma Approach to Wastewater Chemical Processing Specify, Confirm, and Control Raw materials Confirm and Control each step of production Achieve % predictability Less than 1 failure per million events 6σ

15 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 15 The Orlando Story The 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 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 16 The Orlando Story Data, Data, and More Data Wastewater Assume nothing Chase any sustainable or reproducible positive event. Track down every exception, good or bad. LSLUSL

17 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 17 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

18 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 18 The Orlando Story Pilot Work – Full Scale Ahead

19 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 19 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?)

20 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 20 The Orlando Story Projects

21 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 21 The Orlando Story Projects Replaced anaerobic digesters with lime stabilization and NO digestion.

22 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 22 The Orlando Story Pilot Work – Full Scale Ahead

23 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 23 The Orlando Story Data, 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. LSLUSL

24 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 24 The Orlando Story TRAIN Wreck Mechanical versus Automated Control NOT GOOD – Metering post process, daily control

25 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 25 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?

26 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 26 The Orlando Story Process Optimization Accidents DO HAPPEN!

27 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 27 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

28 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 28 The Orlando Story Data, Data, and More Data

29 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 29 The Orlando Story Real Data, Full Scale, Real Time

30 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 30 The Orlando Story Operations Revolt : Round 2 Data Overload Crash & Burn WinCC Replaces WonderWare Data Integrity Update, Upgrade Compatibility $$$, Its always the money

31 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 31 The Orlando Story Everyone, Everything on Board Distributed Control System Redundant Ring & Star Fiber 17 PLCs 55,000 tags ~0.6 GB daily

32 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 32 The Orlando Story Everyone, Everything on Board 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

33 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 33 The Orlando Story Everyone, Everything on Board … and still no Reclaim NPW Demand – 28 mile pipeline Estimated 3 MW pumping capacity Circa 2000 – power outages annually >> 1 min >2 flickers per day per MCC (17 of them) Aluminum 480V and kV on site MV/LV Distribution installed 1968 – 1988 Power Factor 25-40% Demand 6 x average

34 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 34 The Orlando Story … then the light went out Reproducibly, failed lighting ballasts shut down kV !!! 4 independent generator systems, 7 generators 4.4 MW capacity MW demand = uh-oh And they wanted more power

35 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 35 The Orlando Story The Problem 3 bid projects: –$ 9-15 MM New LV distribution New ATSs Open Transition Only Separate Power Control System No harmonics mitigation 2 additional generators No new MV distribution No new MCCs No new transformers

36 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 36 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 MCCs 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

37 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 37 Medium Voltage Switchgear and Distribution Replacement 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!

38 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 38 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

39 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 39 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.

40 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 40 Medium Voltage Switchgear and Distribution Replacement Whats Missing?

41 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 41 Medium Voltage Switchgear and Distribution Replacement Whats Missing? (besides the coffee)

42 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 42 The Orlando Story Real Power – Sleep at Last Whats Missing? Wires Mechanical relays Indicator Lights Buttons Switches Active or passive filters for harmonics REPLACED by use of Profibus DP technology

43 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 43 Medium Voltage Switchgear and Distribution Replacement Installed 2005/2006 – US$ 7.2 MM

44 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 44 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

45 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 45 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 MCCs Interruptible Power Supply Agreement Target: $0.72 per thousand

46 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 46 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

47 Copyright © Key Solutions, Inc All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Key Solutions. Page 47 The Orlando Story Acknowledgements Alan Oyler Guy Mecabe M. Hester E. Ray B. Smith C. Thompson G. Vasquez W. Wood

48 Copyright © Siemens AG All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Siemens. Questions?

49 Copyright © Siemens AG All rights reserved No portion of this document may be reproduced either mechanically or electronically without the prior consent of Siemens. Page 49 Thank you for attending! Gene E. Keyser Key Solutions, Inc. (904)


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