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W. James Gellner, PE Hazen and Sawyer Tom Kutcher, PE ...

W. James gellner , PE Hazen and Sawyer Tom kutcher , PE MSDGC. June 19, 2013. Overview of Ops Tools Examples Process Optimization Use of Tool for Budget Optimization Develop fully calibrated GPS-X models sufficient for wet weather and nutrient removal planning Taylor Creek ( MGD). Indian Creek ( MGD). Polk Run (8 MGD). Little Miami (55 MGD). Sycamore Creek (8 MGD). Muddy Creek (15 MGD). Develop operations tool for plant staff training and operations planning Provide training on models and software Polk Run Taylor Creek Sycamore Indian Creek Mill Creek Muddy Creek Little Miami Intended to be for operations staff use, including training and what-if . Emulate plant operations as close as possible 3-D simplified representation of plant Ops Staff Same scenarios as engineering model Polk Run WWTP.

W. James Gellner, PE – Hazen and Sawyer Tom Kutcher, PE – MSDGC June 19, 2013 Overview of Ops Tools

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Transcription of W. James Gellner, PE Hazen and Sawyer Tom Kutcher, PE ...

1 W. James gellner , PE Hazen and Sawyer Tom kutcher , PE MSDGC. June 19, 2013. Overview of Ops Tools Examples Process Optimization Use of Tool for Budget Optimization Develop fully calibrated GPS-X models sufficient for wet weather and nutrient removal planning Taylor Creek ( MGD). Indian Creek ( MGD). Polk Run (8 MGD). Little Miami (55 MGD). Sycamore Creek (8 MGD). Muddy Creek (15 MGD). Develop operations tool for plant staff training and operations planning Provide training on models and software Polk Run Taylor Creek Sycamore Indian Creek Mill Creek Muddy Creek Little Miami Intended to be for operations staff use, including training and what-if . Emulate plant operations as close as possible 3-D simplified representation of plant Ops Staff Same scenarios as engineering model Polk Run WWTP.

2 Ops Tool GPS-X Model Most plant models are NOT used on a regular basis . Plant Managers Training Plant Operations Process Staff Understanding Engineering Staff Operations Planning Budgeting /. Project Managers Optimization Site Visits Review Develop Develop Detailed Historical Sampling Calibration Initial Model Sampling Date Plan Calibrated Plant Model Plant Input Plant Input Plant Input Graphical Ops Tool Ops Tool Testing / De- Interface Functionality Development Bug Operations Tool Indian Creek WWTP. Take Units In and Out of Service with Mouse Click Can Vary Inputs for Each Unit Process Same Scenarios as Engineering Model Little Miami WWTP Mass / Flow Between Unit Processes Real Time Outputs for Each Unit Process Fly Over Pane for Operating Conditions Based on historical data Includes diurnal variations Steady state and dynamic Long-term simulations Customizable Captures scenario output and real time data MGD (AA).

3 Nitrification limits ( mg/l). Primary clarifiers Conventional activated sludge UV disinfection Gravity thickeners Separate PS/WAS. Significant recycles Haul thickened solids off site for dewatering and incineration RAS. Initial conditions: 8 DO PE. Two tanks in service Zones ML. Summer deg C. Initial Conditions Lower DO. Total Air Req'd CF/day Total Air Req'd CF/day Average Flowrate 1680 CFM Average Flowrate 1500 CFM. Initial Conditions Lower DO. Avg NO3 = mg/l Avg NO3 = mg/l No Change in Effluent NH3. Initial conditions: Two tanks in service Summer deg C. Average flows MGD (summer). Lowered DO in ABs .Lower air requirements /. lower NO3. Effluent TN. Initial ~ 380 lb/day Lower DOs ~270 lb/day OPERATOR QUESTION - Can we do better with our existing plant?

4 How? Plant capacity is 8 MGD, current flow is ~ MGD. Can increase similar to MLE to levels above current rate (currently RAS around MGD). Try RAS at 6 MGD . Lower DO RAS = 6 MGD. Avg TN = 274 lb/day Avg TN = 274 lb/day Huh? RAS = 6 MGD Lower DO AGAIN. RAS = 6 MGD Lower DO AGAIN. Avg TN = 274 lb/day Avg TN= 183 lb/day Avg TN = mg/l Avg TN = mg/l Average Air Flowrate 1550 CFM Average Air Flowrate 1420 CFM. Format is not as important as predictive function .and feedback Learn by doing without violating permit Use is key Ops Tool can be used as key tool in managing budget Process predictions + Cost Compliance at any Compliance at cost optimized cost . Key parameters from simulations used in Energy + Consumables Model Outputs formatted to operations tool interface Ferric Addition UV xx gal (lbs)/year xxkWh/year xx gal (lbs)/Mgal xx kW/Mgal UV.

5 XxkWh/year xx kW/Mgal Simulated Totals Power xxkWh/year xx kW/Mgal Consumables Theoretical vs actual Reasons for difference? Gaps in automation Insufficient staff Instrumentation not measuring actual What is ROI? What is practical? Typically derived from groups of multiple plant processes Sometimes applied without context Don't account for: Level of automated control Level of staff training Physical limitations Is this worth it? Effort/Cost &. O&M. Modify Base Gather Data Ops Tool N. Optimization Strategy Does Ops Is Plant Still Y Make Tool Run Ops in Process Prediction Tool Compliance? Change Match Observed? N Y. Refine Process Monitor and Change ROI? Quantify Benchmarking illustrates opportunity, but can't define endpoint. Ops Tool central to internal optimization Understanding through use and feedback defensible/practical efficiency Continuous progress towards better efficiency Definition of practical endpoints Budget Yr 1 Budget Yr 2 Budget Yr 3.

6 Continuous Improvement Operations tool leverages model development effort for continuous benefit Value is in use / not in appearance Useful tool for internal optimization MSD PBD. Tom kutcher Eric Saylor Rick Riess PM. Bruce Smith Lina Belia, Primodal MSD WWT. WWT Plant Supervisors WWT Operations Staff Hazen & Sawyer Jamie gellner Dan Miklos Hydromantis Ron Latimer Oliver Schraa Katya Bilyk Rajeev Goel Alyssa Mayer Phil Yi


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