moving toward the times

Moving Toward the TimesMoving Toward the Times

Treatment Plant OptimizationTreatment Plant OptimizationByBy

Shawn L. WagnerShawn L. WagnerCity of NewarkCity of Newark

Goals of Plant OperationGoals of Plant Operation

• Production of a safe drinking waterProduction of a safe drinking water

• Production of an aesthetically Production of an aesthetically pleasing drinking waterpleasing drinking water

• Production of drinking water at a Production of drinking water at a reasonable costreasonable cost

Revenue – Water SalesRevenue – Water Sales

• 2007 - 2007 - $5,620,000$5,620,000

• 2008 - 2008 - $5,400,000$5,400,000

• 2009 – Projected 2009 – Projected to be - to be - $5,238,000$5,238,000

5,1005,1505,2005,2505,3005,3505,4005,4505,5005,5505,6005,650

2007 2009

WaterSales

Treatment Plant Budget Treatment Plant Budget Analysis Analysis

Wages

Chemicals

Supplies/ mis

Maint/ Equip

Utilites

Where Do You Start?Where Do You Start?

• Rate IncreaseRate Increase– Pass it on to the customers?Pass it on to the customers?– At this point it is not an option.At this point it is not an option.– YET!YET!

• StaffingStaffing• Chemicals Chemicals • UtilitiesUtilities• Maintenance & EquipmentMaintenance & Equipment

StaffingStaffing– OvertimeOvertime

•Calling in Maintenance for equipment failureCalling in Maintenance for equipment failure– RedundancyRedundancy– Use your best judgmentUse your best judgment– If your not sure CALL Your SupervisorIf your not sure CALL Your Supervisor

•Water Main BreaksWater Main Breaks– Can it wait until normal business hours?Can it wait until normal business hours?

Small Leak?Small Leak?

•Special Bacteria TestingSpecial Bacteria Testing– In house testing plan around Certified PersonalIn house testing plan around Certified Personal

ChemicalsChemicals– Powdered Activated CarbonPowdered Activated Carbon– Potassium PermanganatePotassium Permanganate– Ferric SulfateFerric Sulfate– QuicklimeQuicklime– Carbon dioxideCarbon dioxide– Sodium HypochloriteSodium Hypochlorite– OrthophosphateOrthophosphate– FluorideFluoride

Chemical Cost in 2007Chemical Cost in 2007

• Quicklime – $223,200Quicklime – $223,200

• Sodium Hypochlorite – $30,444.20Sodium Hypochlorite – $30,444.20

• Fluoride – $14,500Fluoride – $14,500

• Powdered Activated Carbon - $79,680Powdered Activated Carbon - $79,680

• Ferric Sulfate - $108,637Ferric Sulfate - $108,637

• Carbon Dioxide - $19,800Carbon Dioxide - $19,800

• Potassium Permanganate - $14,400Potassium Permanganate - $14,400

• Orthophosphate - $14,900Orthophosphate - $14,900

Chemical Cost in 2009Chemical Cost in 2009

• Quicklime – $219,600Quicklime – $219,600

• Sodium Hypochlorite – $54,926Sodium Hypochlorite – $54,926

• Fluoride – $36,200Fluoride – $36,200

• Powdered Activated Carbon - $146,560Powdered Activated Carbon - $146,560

• Ferric Sulfate - $212,857Ferric Sulfate - $212,857

• Carbon Dioxide - $19,350Carbon Dioxide - $19,350

• Potassium Permanganate - $18,150Potassium Permanganate - $18,150

• Orthophosphate - $44,950Orthophosphate - $44,950

20072007 20092009• Quicklime – $223,200Quicklime – $223,200

• Hypochlorite – $30,444Hypochlorite – $30,444

• Fluoride – $14,500Fluoride – $14,500

• PAC – $79,680PAC – $79,680

• Ferric Sulfate - Ferric Sulfate - $108,637$108,637

• Carbon Dioxide - Carbon Dioxide - $19,800$19,800

• Permanganate - Permanganate - $14,400$14,400

• Phosphate - $14,900Phosphate - $14,900

• Quicklime – $219,600Quicklime – $219,600

• Hypochlorite – $54,926Hypochlorite – $54,926

• Fluoride – $36,200Fluoride – $36,200

• PAC - $146,560PAC - $146,560

• Ferric Sulfate - Ferric Sulfate - $212,857$212,857

• Carbon Dioxide - Carbon Dioxide - $19,350$19,350

• Permanganate - Permanganate - $18,150$18,150

• Phosphate - $44,950Phosphate - $44,950

Quic

klim

e, -1

.6%

Sodiu

m H

ypo, 44.6

%

Flu

ori

de, 60.0

%

PAC, 45.6

%

Ferr

ic S

ulfate

, 49.0

%

Carb

on D

ioxid

e, -2

.3%

Pot.

Perm

., 2

0.7

%

Ort

hophosp

hate

, 66.9

%

-10.0%

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

% Chemical Cost for 2007 - 2009

QuicklimeSodium HypoFluoridePACFerric SulfateCarbon DioxidePot. Perm.Orthophosphate

Re-Think TreatmentRe-Think Treatment

• Where can we make adjustment?Where can we make adjustment?– Fluoride Fluoride

• The optimal level is 1.0mg/lThe optimal level is 1.0mg/l

• The low end is 0.8mg/lThe low end is 0.8mg/l

– The source water has a level of 0.2mg/lThe source water has a level of 0.2mg/l– Current feed rate is 0.8mg/lCurrent feed rate is 0.8mg/l– Make feed rate adjustment to .65mg/lMake feed rate adjustment to .65mg/l

• How can 0.15mg/l make a difference?How can 0.15mg/l make a difference?– Lets Break it downLets Break it down

FluorideFluoride

(0.8mg/l) (7.3MGD) (100) (0.8mg/l) (7.3MGD) (100)

(23%) (0.79wt.F) (24hrs) (1.18SG)(23%) (0.79wt.F) (24hrs) (1.18SG)

= 1.13gal/hr= 1.13gal/hr

(0.65mg/l) (7.3MGD)(0.65mg/l) (7.3MGD) (100)(100)

(23%) (0.79wt.F) (24hrs) (1.18SG)(23%) (0.79wt.F) (24hrs) (1.18SG)

= 0.92gal/hr= 0.92gal/hr

Fluoride - cont.Fluoride - cont. 1.13 gal/hr1.13 gal/hr

-- 0.92 gal/hr0.92 gal/hr

== 0.21 gal/hr0.21 gal/hr (24hr/day) = (24hr/day) = 5.10 gal/day5.10 gal/day

(365days/yr) = 1860.1 gal/yr(365days/yr) = 1860.1 gal/yr

(1860.10 gallons/year) ($3.62 per gallon)(1860.10 gallons/year) ($3.62 per gallon)

Savings ofSavings of=$6,733.57/year=$6,733.57/year

Ferric SulfateFerric Sulfate

• Back to the Basics Back to the Basics – Jar TestingJar Testing

•Not sure how?Not sure how?– Take a Class, Perhaps OTCO?Take a Class, Perhaps OTCO?

•Dosages in 2007Dosages in 2007– Winter – 15mg/lWinter – 15mg/l– Summer – 10mg/lSummer – 10mg/l

– After jar testing After jar testing •Dosages in 2008Dosages in 2008

– Winter – 7mg/lWinter – 7mg/l– Summer – 5mg/lSummer – 5mg/l

Ferric Sulfate – Winter Nov-Ferric Sulfate – Winter Nov-AprilApril(15mg/l) (9.3MGD) (100)(15mg/l) (9.3MGD) (100)

(45%) (1.55 S.G.) (24hrs)(45%) (1.55 S.G.) (24hrs)

= 8.33 gal/hr= 8.33 gal/hr

(7.0mg/l) (9.3MGD) (100)(7.0mg/l) (9.3MGD) (100)

(45%) (1.55 S.G.) (24hrs)(45%) (1.55 S.G.) (24hrs)

= 3.89 gal/hr= 3.89 gal/hr

Ferric – Winter is based on Ferric – Winter is based on 181days181days

8.33 gal/hr8.33 gal/hr

-- 3.89 gal/hr3.89 gal/hr

== 4.44 gal/hr 4.44 gal/hr

(24hr/day) = 106.67 gal/day(24hr/day) = 106.67 gal/day

(181days/Bi-yr) = 19,307 gal/bi-yr(181days/Bi-yr) = 19,307 gal/bi-yr

(19,307gal/bi-yr) (8.34Lbs/gal) (1.55S.G.) (12%) = 29,949 (19,307gal/bi-yr) (8.34Lbs/gal) (1.55S.G.) (12%) = 29,949 lbslbs

(29,949Lbs 12% Fe/year) ($1.53 per lb of 12% Fe)(29,949Lbs 12% Fe/year) ($1.53 per lb of 12% Fe)

Savings ofSavings of = $45,822.39/Biannually= $45,822.39/Biannually

Ferric Sulfate – Summer May-Ferric Sulfate – Summer May-OctOct

(10mg/l) (9.3MGD) (100)(10mg/l) (9.3MGD) (100)

(45%) (1.55 S.G.) (24hrs)(45%) (1.55 S.G.) (24hrs)

= 5.56 gal/hr= 5.56 gal/hr

(5.0mg/l) (9.3MGD) (100)(5.0mg/l) (9.3MGD) (100)

(45%) (1.55 S.G.) (24hrs)(45%) (1.55 S.G.) (24hrs)

= 2.78 gal/hr= 2.78 gal/hr

Ferric – Summer based on 184 Ferric – Summer based on 184 daysdays

5.56 gal/hr5.56 gal/hr

-- 2.78 gal/hr2.78 gal/hr

== 2.78 gal/hr 2.78 gal/hr

(24hr/day) = 66.67 gal/day(24hr/day) = 66.67 gal/day

(184days/Bi-yr) = 12,067 gal/bi-yr(184days/Bi-yr) = 12,067 gal/bi-yr

(12,067gal/bi-yr) (8.34Lbs/gal) (1.55S.G.) (12%) = 18,718 (12,067gal/bi-yr) (8.34Lbs/gal) (1.55S.G.) (12%) = 18,718 lbslbs

(18,718Lbs 12% Fe/year) ($1.53 per lb of 12% Fe)(18,718Lbs 12% Fe/year) ($1.53 per lb of 12% Fe)

Savings ofSavings of = $28,638.99/Biannually= $28,638.99/Biannually

Total Ferric Cost SavingsTotal Ferric Cost Savings

• Winter Winter – $45,822.39– $45,822.39

• Summer Summer – $28,638.99– $28,638.99

• Total Yearly savings = $74,461.38Total Yearly savings = $74,461.38

Powdered Activated Powdered Activated CarbonCarbon & &Potassium PermanganatePotassium Permanganate

• Why are we feeding these Why are we feeding these chemicals?chemicals?

• Is one single treatment process Is one single treatment process applicable to all taste and odor applicable to all taste and odor problems? problems?

Why are we feeding Why are we feeding Chemicals?Chemicals?• Taste & Odors are the most common Taste & Odors are the most common

and difficult problems that confront and difficult problems that confront water operatorswater operators

• Biological Growth in Source WaterBiological Growth in Source Water– GeosminGeosmin

•A natural chemical by-product of various A natural chemical by-product of various species of blue-green algaespecies of blue-green algae

– (earthy odor)(earthy odor)

– Filamentous Bacterial GrowthFilamentous Bacterial Growth•Grows in sediments, water, and aquatic plant Grows in sediments, water, and aquatic plant

life.life.– (earthy-musty taste & odor)(earthy-musty taste & odor)

Is one single treatment process Is one single treatment process applicable to all taste and odor applicable to all taste and odor problems?problems?

• Because both chemicals have a Because both chemicals have a different function an evaluation of the different function an evaluation of the source water should be done.source water should be done.

• Just a couple of things to look at before Just a couple of things to look at before making adjustments?making adjustments?– TOC levelsTOC levels– Atrazine levelsAtrazine levels

Taste & Odor ControlTaste & Odor Control

• Powdered Activated CarbonPowdered Activated Carbon– AdsorptionAdsorption– Most common technique usedMost common technique used– Wood, Coal, Coconut shells, or BonesWood, Coal, Coconut shells, or Bones

Taste & Odor ControlTaste & Odor Control

• Potassium Permanganate (KMnO4)Potassium Permanganate (KMnO4)•Strong OxidizerStrong Oxidizer

•Destroys many organic compoundsDestroys many organic compounds– Natural and manufacturedNatural and manufactured

•Commonly used to oxidize iron and Commonly used to oxidize iron and manganesemanganese

2007 – 2009 Review2007 – 2009 Review

• Powdered Powdered Activated Carbon Activated Carbon Increase by 45.6%Increase by 45.6%

• Potassium Potassium Permanganate Permanganate Increase by 20.7%Increase by 20.7%

0500

100015002000250030003500400045005000

2007 2009

(PAC)CarbonPot.Perm.

Total Estimated Chemical Total Estimated Chemical Cost/Yr.Cost/Yr.

$0

$100,000

$200,000

2007 2008 2009

PAC

$0

$5,000

$10,000

$15,000

$20,000

2007 2008 2009

Potassium Permanganate

• Powdered Activated Carbon (2007) - $79,680Powdered Activated Carbon (2007) - $79,680• Powdered Activated Carbon (2009) – $146,560Powdered Activated Carbon (2009) – $146,560

• Potassium Permanganate (2007) - $14,400Potassium Permanganate (2007) - $14,400• Potassium Permanganate (2009) – $18,150Potassium Permanganate (2009) – $18,150

No Brainier No Brainier

• Shut off the CarbonShut off the Carbon

• Potassium injected at the beginning Potassium injected at the beginning of the Pre oxidation basin feed rate of the Pre oxidation basin feed rate 0.7mg/l0.7mg/l

Weighed the benefitsWeighed the benefits

PAC – Winter Nov-AprilPAC – Winter Nov-April

(5mg/l) (7.6 MGD) (100)(5mg/l) (7.6 MGD) (100)

(10.7%) (24hrs)(10.7%) (24hrs)

= 14.8 = 14.8 gal/hrgal/hr

(0.0mg/l) (7.6 MGD) (100)(0.0mg/l) (7.6 MGD) (100)

(45%) (24hrs)(45%) (24hrs)

=0.00 gal/hr=0.00 gal/hr

PAC – PAC – 14.80 gal/hr14.80 gal/hr

-- 0.00 gal/hr 0.00 gal/hr

== 14.80 gal/hr 14.80 gal/hr (24hr/day) = (24hr/day) = 355.14 gal/day355.14 gal/day

(365days/yr) = 64,280 gal/yr(365days/yr) = 64,280 gal/yr

(64,280 gallons/year) ($0.916 per lbs)(64,280 gallons/year) ($0.916 per lbs)

1 lb = 1 gallon1 lb = 1 gallon

Savings ofSavings of=$6,733.57/year=$6,733.57/year

Treatment ProcessTreatment Process

• Source WaterSource Water– North Fork Licking RiverNorth Fork Licking River

• IntakeIntake– Bar RackBar Rack

•Protect down stream equipment (pumps) from Protect down stream equipment (pumps) from large debrislarge debris

– Traveling ScreenTraveling Screen•Filters out smaller debris (leaves, sticks, & Filters out smaller debris (leaves, sticks, &

fish) fish)

• Low Service PumpsLow Service Pumps– Four 12” Flygt Pumps that range from 4 Four 12” Flygt Pumps that range from 4

MGD to 8 MGDMGD to 8 MGD•Two - 8 MGDTwo - 8 MGD

– 60Hp60Hp

•One - 6 MGDOne - 6 MGD– 45Hp45Hp

•One - 4 MGDOne - 4 MGD– 30Hp30Hp

CoagulantCoagulant

• Chemicals that cause very fine Chemicals that cause very fine particles to clump (floc) together into particles to clump (floc) together into larger particles.larger particles.– Ferric SulfateFerric Sulfate– Ferric ChlorideFerric Chloride– Aluminum SulfateAluminum Sulfate– PolymersPolymers

SofteningSoftening

• Basic methods of softening a municipal Basic methods of softening a municipal water supply are chemical precipitation and water supply are chemical precipitation and ion exchangeion exchange

• ChemicalChemical– LimeLime

• QuicklimeQuicklime• Hydrated limeHydrated lime

• Ion exchangeIon exchange– Exchanging hardness causing ions (calcium & Exchanging hardness causing ions (calcium &

Magnesium) for the sodium ions to create soft Magnesium) for the sodium ions to create soft water.water.

Physical TreatmentPhysical Treatment

• CoagulationCoagulation

• FlocculationFlocculation

• SedimentationSedimentation

• FiltrationFiltration

CoagulationCoagulation

• The term coagulation describes the The term coagulation describes the effect produced when certain effect produced when certain chemicals are added to raw water chemicals are added to raw water containing slowly settling or containing slowly settling or nonsettleable particlesnonsettleable particles

Flash MixFlash Mix

• Two flash mix basins are providedTwo flash mix basins are provided– One to be in-service and the other as a One to be in-service and the other as a

standbystandby– Variable speed motorVariable speed motor

• Lime SlurryLime Slurry– SofteningSoftening

• Ferric SulfateFerric Sulfate– CoagulantCoagulant

Optimizing TreatmentOptimizing Treatment

• Ferric SulfateFerric Sulfate– CoagulantCoagulant

0

2

4

6

8

10

12

Spring Fall

200720082009

IntakesIntakes

• Trash RackTrash Rack– Protect downstream pumpsProtect downstream pumps– The Intakes are located on the The Intakes are located on the

west bank, which is east of the west bank, which is east of the plant. The river runs north to plant. The river runs north to south. There are two intake south. There are two intake buildings and are similar in buildings and are similar in design. The intakes have a design. The intakes have a rotating screen following a rotating screen following a trash rack with a four inch trash rack with a four inch spacing to prevent large debris spacing to prevent large debris from entering and damaging from entering and damaging pumping equipment pumping equipment downstream. A thirty-six inch downstream. A thirty-six inch main runs from each of the main runs from each of the screen houses. There are two screen houses. There are two butterfly valves one for each butterfly valves one for each line and one that inter-line and one that inter-connects both lines incase the connects both lines incase the need to repair or service part need to repair or service part of the main.of the main.

• Rotating ScreenRotating Screen– Leaves, and smaller debrisLeaves, and smaller debris

Raw Water PumpLow Service pumps

Chlorine injectorNo longer used as

an oxidantPotassium permanganate

Oxidizes taste & odors

Powered Activated Carbon(PAC)

Adsorbs Taste & odorsReduces

Total Organic Carbons(TOC)

Optimizing Taste & Odor Optimizing Taste & Odor TreatmentTreatment

0102030405060708090

100

2006 2007 2008 2009

CarbonPotassium

Plant MaintenancePlant Maintenance

• Maintenance ProgramMaintenance Program– Planning & SchedulingPlanning & Scheduling– Records ManagementRecords Management– Spare Parts ManagementSpare Parts Management– Cost and Budget ControlCost and Budget Control– Emergency Repair ProceduresEmergency Repair Procedures– Training ProgramTraining Program

SuppliesSupplies– Laboratory & Equipment PartsLaboratory & Equipment Parts

•Let the supplier stock it for you Let the supplier stock it for you – Order what you NeedOrder what you Need

•Delivery timeDelivery time

– JanitorialJanitorial•Do you need it?Do you need it?

•Shop aroundShop around

– OfficeOffice•Paper/Toner or InkPaper/Toner or Ink

– Print ONLY what you needPrint ONLY what you need

– Do your part & Recycle Do your part & Recycle