OPERATIONAL OPTIMIZATION 2013 KY/TN WEA Management Conference M. Shannon Lambert, P.E. PRESENTED BY:

Operational Optimization EUM Definition Ensures ongoing, timely, cost- effective, reliable, and sustainable performance improvements in all facets of its operations. Minimizes resource use, loss, and impacts from day-to-day operations. Maintains awareness of information and operational technology developments to anticipate and support timely adoption of improvements. 2

Operational Optimization Energy represents the largest controllable cost of providing water or wastewater services to the public. Most facilities were designed and built when energy costs were not a major concern. Conservative designs, high safety factors and designs based on lowest capital costs have led to energy inefficient facilities. 3KY/TN WEA MANAGEMENT CONFERENCE

Operational Optimization Wastewater Treatment Energy Costs Are Rising Due To Many Factors: – More Stringent Effluent Requirements – Enhanced Biosolids Treatment – Aging Collection Systems Resulting in Increased I/I Flows – Increase in Electricity Costs 4KY/TN WEA MANAGEMENT CONFERENCE

Operational Optimization Process Optimization – Maximize Capacity – Improve Effluent Quality – Improve Reliability Energy Optimization – Reduce Energy Consumption – Reuse Renewable Resources – Reduce Green House Gas (GHG) Emissions 5KY/TN WEA MANAGEMENT CONFERENCE

Energy Optimization 6

Approach to Energy Optimization Establish Baseline Energy Use Benchmark Performance Conduct an Energy Audit Develop Goals Identify Best Practices/Energy Conservation Measures (ECMs) Prioritize Projects Implement Improvements Monitor and Measure Results Communicate Success 7KY/TN WEA MANAGEMENT CONFERENCE

Energy Benchmarking Create a baseline of energy performance against which you can measure improvements. ENERGY STAR’s Benchmarking Tool, ( drinking_water) drinking_water ENERGY STAR offers plant energy performance indicators (EPIs) to enable energy managers to evaluate the energy efficiency of their plants relative to that of the industry. 8KY/TN WEA MANAGEMENT CONFERENCE

Energy Benchmarking Results from Study Performed by Pacific Gas and Electric Company 9KY/TN WEA MANAGEMENT CONFERENCE

Energy Benchmarking 10KY/TN WEA MANAGEMENT CONFERENCE

Energy Benchmarking 11KY/TN WEA MANAGEMENT CONFERENCE

Energy Consumption 12KY/TN WEA MANAGEMENT CONFERENCE

Pumping Optimization Match Pump Capacity with Demands (Right Sizing) Replace Inefficient Pumps – Desired Efficiency 60-70% Install Premium Efficiency Motors Utilize VFDs 13KY/TN WEA MANAGEMENT CONFERENCE

Pump System Assessment Tool The Department of Energy (DOE) has developed and supports the Pump System Assessment Tool (PSAT), available free online at at.html at.html Benefits of PSAT – Establish system efficiency – Quantify potential energy savings – Examine the economic and energy impacts of different operating scenarios – Provide data for trending system performance – Clarify impacts of operational changes on demand charges – Identify degraded or poorly performing pumps. 14KY/TN WEA MANAGEMENT CONFERENCE

Brentwood Pump Station Evaluation 9.5 mgd wastewater pumping station – Dry pit submersible pumps Pump Performance Testing – Flowrate – Pressure (converted to head) – Electrical Power 15KY/TN WEA MANAGEMENT CONFERENCE

Pumping System Assessment Tool 16KY/TN WEA MANAGEMENT CONFERENCE

Pumping System Assessment Tool 17KY/TN WEA MANAGEMENT CONFERENCE

Pump Station Flowrate Histogram 18KY/TN WEA MANAGEMENT CONFERENCE

Brentwood Pump Station Results of the Analysis – Limit Single Pump Speed to 55 Hz – Minimize Cavitation at Higher Speeds – Dual Pump Performance (gpm/kW) Was Higher Than Single Pump at Flows Above 4,000 gpm – Installation of Smaller “Pony Pump” Not Cost Justifiable – Raising Wetwell Level Almost as Effective as Adding Fourth Pump – Change in Flushing Protocol Could Reduce Demand Charge 19KY/TN WEA MANAGEMENT CONFERENCE

Aeration Optimization Proper Sizing of Blowers – Should be sized for 5:1 turndown ratio If Blowers are Oversized – Replace with one or more smaller blowers – Install VFDs – Install Inlet Throttling Valve, if applicable Dedicated Blowers for Channel Aeration (Large Plants) 20KY/TN WEA MANAGEMENT CONFERENCE

Blower Types 21 KY/TN WEA MANAGEMENT CONFERENCE

Blower Efficiencies 22 KY/TN WEA MANAGEMENT CONFERENCE

Blower Optimization Literature Review Case Study Waukesha, WI – 18.5 mgd conventional activated sludge – Six aeration basins w/fine-bubble diffusers – Five 700 hp inlet throttled centrifugal blowers – Reduction in industrial load – mg/L DO with one blower – Replaced two 700 hp blowers with 350 hp blowers – Implement most open valve DO control – Saving 1,000,000kWh per year (9% of total plant energy) – 3 yr. payback 23KY/TN WEA MANAGEMENT CONFERENCE

Aeration Optimization Diffuser Selection and Configuration Can Reduce Energy Consumption – Tapered Diffuser Configuration – Fine Bubble Diffusers – Test OTE using off-gas testing Nashville MWS Dry Creek WWTP – Before Optimization Coarse Bubble Diffusers Evenly Spaced Inability to Maintain Consistent DO Across the Basin Existing Blower Capacity – 45,000SCFM – Coarse Bubble Tapered Air – 65,000 SCFM – Fine Bubble Tapered Air – 39,700 SCFM 24KY/TN WEA MANAGEMENT CONFERENCE

Dry Creek DO Profile – Pre-Optimization 25KY/TN WEA MANAGEMENT CONFERENCE

Aeration Optimization JEA Case Study – Replaced 10 – 100 hp multi-stage centrifugal blowers with 6 – 200 hp turbo blowers. – Replaced Schreiber counter- current aeration system with fine bubble diffusers. – Power consumption reduced from 1,000 hp to 400 hp. – Reduced operating cost more than $75,000 annually. 26KY/TN WEA MANAGEMENT CONFERENCE

Aeration Optimization Automated DO Control – Tight DO control can save 10-30% of total energy costs. 27KY/TN WEA MANAGEMENT CONFERENCE

Digester Gas Utilization Options 28KY/TN WEA MANAGEMENT CONFERENCE

Combined Heat & Power Technologies 29KY/TN WEA MANAGEMENT CONFERENCE

Digester Gas Utilization Reading, PA – New 28.5 MGD WWTP 30Water Services Business Plan

Digester Gas Utilization 31

Reading, PA WWTP Evaluation Conclusions Anaerobic digesters are net producers of energy that can be applied to other processes such as drying of solids or generation of power. Biogas generated through the digestion process can provide enough energy to heat the digesters and provide building heat. The boilers provided for the digester heating process can also support the building heat requirements. Use of an engine generator or micro turbines with biogas is cost effective at $0.1036/kWh. The cost savings will increase with higher purchased electricity rates. 32KY/TN WEA MANAGEMENT CONFERENCE

Co-Digestion of FOG Adding the captured high-strength FOG waste to conventional anaerobic biosolids digestion can result in: – added revenue from grease tip fees, – increased biogas production, – enhanced gas utilization potential, and – Potentially increased volatile solids destruction of the biosolids. 33KY/TN WEA MANAGEMENT CONFERENCE

FOG Co-Digestion Lifecycle Costs 34KY/TN WEA MANAGEMENT CONFERENCE

Alternative Funding Options Grants and Incentives Performance Based Energy Incentives Renewable Energy Financing Power Purchase Agreements Third Party Performance Contracts 35KY/TN WEA MANAGEMENT CONFERENCE

Energy Services Performance Contracting Energy Performance Contracts (EPCs) Can Be Considered in Operating Budget Instead of Capital Budget Energy Services Company (ESCOs) usually develop and manage EPCs and assume most of the technical and performance risk 36KY/TN WEA MANAGEMENT CONFERENCE

Energy Services Performance Contracting 37KY/TN WEA MANAGEMENT CONFERENCE Performance contracting leverages the cost savings from energy conservation measures (ECMs) to provide the capital to make energy efficiency improvements: Performance contracting is revenue/budget neutral It uses the money already spent on energy to fund infrastructure improvements Energy efficient upgrades yield savings that pay for the improvements Additional savings can be used to lower operating costs or invest in additional improvements Return on investment is 100%+

Summary Wastewater and water utilities’ challenges in meeting energy needs and costs are increasing. Every dollar spent on energy is a dollar that it is not available for employee wages/benefits or to stabilize utility rates. Proactively and systematically looking for ways to reduce energy consumption and costs is a critical part of managing operations. A better managed, more efficient utility enjoys an improved image, position, and relationships with regulatory agencies as well as tax or rate payers 38KY/TN WEA MANAGEMENT CONFERENCE

QUESTIONS?