managing%multiple%variables:%%% … · natural gas use $28,867 $28,867 total additional costs...

2/2/15

KENT A LACKEY, P.E.

MANAGING MULTIPLE VARIABLES: WW TREATMENT OPTIMIZATION AND REAL-‐TIME ENERGY MANAGEMENT

Winston-‐Salem/Forsyth County UMlity Commission •  Ron Hargrove, U.lity Director •  Courtney Driver, Deputy U.lity Director •  Frank Crump, WW Superintendent •  Chris Shamel, Asst WW Superintendent •  Keith Jones, Muddy Creek WWTP ORC

Black & Veatch •  Bob Wimmer, Process Engineer •  Bahareh Karami, Civil Engineer •  Jeff Neeman, SII Water Technology Manager

ACKNOWLEDGEMENTS

• Background •  Performance Management • Winston Salem Wastewater System

• MCWWTP Consolidated Influent Pumping

• MulM-‐Plant OpMmizaMon

PRESENTATION OUTLINE

3

• Data Overload • OperaMonal Complexity

• Skilled Workforce Shortage

• Aging Assets • Tight OperaMng Margins

• VolaMle Markets (Chemicals, Energy, Financial)

• Regulatory Compliance + Future Uncertainty

Analytics can leverage utility-‐wide data

BACKGROUND – PERFORMANCE MANAGEMENT KEY INDUSTRY ISSUES DRIVING NEED FOR SMART ANALYTICS

4

Do we Make Decisions Based on the Past or the Future?

BACKGROUND – PERFORMANCE MANAGEMENT HOW DO WE OPERATE TODAY

5

• SCADA is the Lifeblood of our WWTP • Data and Trending •  Automated Controls •  Equipment Monitoring

• Laboratory TesMng • Understanding Health of our Process i.e. “Process Control”

•  Validated Compliance

• Wastewater System or OperaMons Management? OpMmizaMon?

BACKGROUND – PERFORMANCE MANAGEMENT WHAT DECISIONS ARE WE NOT MAKING BECAUSE THEY ARE TOO COMPLEX?

6

• Flow Management • What is my hourly system projec.on? •  Can I predict my treatment loads?

• Carbon Management •  Should I be driving carbon towards my BNR basins or my digesters?

• Does the answer change day to day? Hour to hour?

• Energy Management •  Can I make demand response work for me?

• TransiMon from point soluMons to enterprise focus • Shie toward forward-‐looking, predicMve analyMcs • Deeper immersion of tools within processes • Stronger focus on business value

BACKGROUND – PERFORMANCE MANAGEMENT DATA ANALYTICS TRENDS

7

“Whether breaking down business silos, or integra5ng data and technologies,

these efforts scream for some sort of centralized effort within a company to

coordinate the many groups involved.” (UMlity AnalyMcs InsMtute)

BACKGROUND – PERFORMANCE MANAGEMENT SMART INTEGRATED INFRASTRUCTURE IS A JOURNEY

8

Integration Progressionlow

low

high

Strategic Im

pact

Industry Average

I. Smart Networkl Device Connectivityl Smart Grid

Data Information Knowledge

II. Smart Informationl Data Aggregation and Analysisl Smart Single-‐Use Infrastructure

III. Smart Utilityl Multi-‐System – Multi-‐Facility

Aggregation

IV. Smart Infrastructurel Multi-‐Utility Integration l Physical – Cyber Integration

IV. Smart Infrastructurel Multi-‐Utility Integration l Physical – Cyber Integration

Market T

oday

Industry Defining

high

Industry Best

Wisdom

• Winston-‐Salem/Forsyth County UMlity Commission •  Approximately 122,000 customers (3rd largest in NC) •  2 WWTPS

•  Muddy Creek •  21 mgd capacity

•  Archie Elledge •  30 mgd capacity

•  Three Drainage Basins •  South Fork •  Muddy Creek •  Elledge

•  49 WW Li` Sta.ons •  1,723 miles of sewer

BACKGROUND – WASTEWATER SYSTEM

9

Archie Elledge WWTP

Muddy Creek WWTP

•  introducMons

BACKGROUND – WASTEWATER SYSTEM LONG TERM WASTEWATER TREATMENT ANALYSIS

10

Archie Elledge WWTP

Muddy Creek WWTP

Muddy Creek Basin

South Fork Basin

Elledge Basin

South Fork PS New MC

Transfer PS

• Where is it being generated?

•  Convey all flows to plants using exis.ng infrastructure

•  Transfer flows between plants

•  Transfer flows between basins

•  System Equaliza.on •  Scalping within the collec.on system

•  Future New Plant

Future Plant OpMon 1

Future Plant OpMon 1

BACKGROUND – WASTEWATER SYSTEM FINAL LONG TERM WWT OPTION

11 11

• Maintain Two WWTP System

•  Transfer Pump Sta.on at MCWWTP to Convey Flow to AEWWTP

•  Abandon South Fork Pump Sta.on

NOTE: CollecMon system piping must convey all flows to the WWTPs and SFPS from the collecMon system

Archie Elledge WWTP

Muddy Creek WWTP

Muddy Creek Basin

South Fork Basin

Elledge Basin

South Fork PS New MC

Transfer PS

MCWWTP CONSOLIDATED INFLUENT PUMPING SYSTEM

12

MCWWTP CONSOLIDATED INFLUENT PUMPING OVERVIEW

13

Archie Elledge WWTP

Muddy Creek WWTP

Transfer Force Main

13

•  MCWWTP •  All Flow Enters CIPS and is Pumped •  Pumps to Day Tanks (Overflow to Storm EQ during high rain

events) •  Operator can set a fixed rate for MCWWTP •  Operator can set a fixed rate for Transfer to AEWWTP

MCWWTP CONSOLIDATED INFLUENT PUMPING OVERVIEW

14

MCWWTP CONSOLIDATED INFLUENT PUMPING PERFORMANCE MANAGEMENT

15

•  Influent Performance Management System is in Development •  Flow Management Between Plants •  Leverage Influent Storage to Op.mize Energy Use •  Provide Capability to Forecast Impacts of Changes •  Real-‐Time Energy Use and Cost Based on Rate Schedule

•  Leveraging Data •  Online sampling of influent COD/TOD •  Online flow measurement, process level energy

consump.on and chemical consump.on

MCWWTP CONSOLIDATED INFLUENT PUMPING PERFORMANCE MANAGEMENT

16

•  UMlizing AnalyMcs to Make Smart Decisions •  Analyze cost of treatment at each plant ($/unit flow) •  Consider Energy Use, Aera.on Efficiency, Process

Performance •  Recommend Flow Transfer Amount and MCWWTP Flow

•  Achieve Op.mal Treatment Cost

•  AddiMonal Benefits •  Assess Treatment Performance •  Iden.fy Op.miza.on Opportuni.es at each Plant

MULTI-‐PLANT OPTIMIZATION OPPORTUNITIES

17

• OpMmizaMon and Energy Management Study •  Aera.on System Modifica.ons for DO Distribu.on •  Sidestream Treatment for Ammonia Removal • Op.mized Chlorine Dosing Using Real Time Demand •  SRT/Aera.on Basin Solids Control via Online Analyzers • Digester Gas U.liza.on

•  Combined Heat and Power •  Aera.on Blowers •  Vehicle Fuel CNG

•  Pumping Monitoring and Efficiency Driven Controls

MULTI-‐PLANT OPTIMIZATION OVERVIEW

18

• Current Process •  4 Opera.ng Basins with 20 stages each •  Stage 1 Anaerobic •  Stages 6, 11, 16 are Swing Zones (currently aerated)

•  Remaining Stages are Aerobic •  Single DO Control Point in Each Basin

MULTI-‐PLANT OPTIMIZATION AERATION-‐ AEWWTP

19

• Result: •  Excess Generally U.lized to Ensure DO Setpoint is Met

• AddiMonal Energy Loss – Header has Many Leaks

• OpMmizaMon Opportunity: •  Segregate Aera.on Basin into Separate Control Zones •  Evaluated Mul.ple Configura.ons – 4 Zone Selected •  4-‐5 Aera.on Stages per zone •  Control Zones will have Independent DO Probe/Air Supply

•  Replace Exis.ng Header • Benefits:

•  Project Air flow Reduc.on •  7,300 scfm at AA Condi.ons •  5,900 scfm at MM Condi.ons

•  $186,000 Savings Per Year in Net Power Reduc.on

MULTI-‐PLANT OPTIMIZATION AERATION-‐ AEWWTP

20

• Basic Controls: DO Control Loop for Each Zone • Performance Management System

• Monitor Zone DO Demand and Process Performance to Tune DO Control Loops

•  Equipment Efficiency •  Assess Op.mal Blower Opera.on to Minimize Cost •  Forecast Aera.on Demand Based on Influent COD/TOD •  Evaluate Blower Efficiency Trend – Iden.fy Replacement or Upgrade Need

•  Leverage Diurnal EQ and Storm EQ to Assess Daily Opera.ng Setpoints that Minimize Aera.on Cost

MULTI-‐PLANT OPTIMIZATION AERATION – PERFORMANCE MANAGEMENT

21

• Digester Gas UMlizaMon Study – CHP Preferred OpMon • Allows Digester Gas Use and Emergency Power in One System – Reducing Combined Capital Cost •  Eliminates Addi.onal Emergency Diesel Generators • Maximizes Digester Gas Use for Full Plant Power •  800kW of Power Genera.on from DG •  1.1MW of Emergency Power Genera.on with NG Supplement

• Provides Heat Recovery –Generator Waste Heat Used to Create Hot Water for Digester HeaMng (reducing natural gas consumpMon of boilers)

MULTI-‐PLANT OPTIMIZATION CHP– MCWWTP

22

23


Natural Gas Supplement

• Generator OperaMon • Operate at Full Load During Peak Power Period of Day •  Supplement with NG if Cost Beneficial

• Performance Management System •  Provide Recommenda.ons Regarding Op.mal Time of Day to Operate

•  Assess Cost Benefit of NG Supplement •  Track Power Genera.on and Revenue •  Track Generator Performance and Efficiency •  Real Time KPI Monitoring (DG Produc.on/Storage, Thermal/Electrical Output, Equipment Up.me)

MULTI-‐PLANT OPTIMIZATION CHP– PERFORMANCE MANAGEMENT

24

MULTI-‐PLANT OPTIMIZATION CHP– PERFORMANCE MANAGEMENT

25

• Winston Salem is Making HolisMc Decisions to Provide Long Term Treatment Flexibility and OpMmizaMon

• Winston-‐Salem will Benefit from State of the Art Performance Management •  Provides the Ability to Track Energy and Cost • Online Performance Op.miza.ons • Holis.c Treatment Decisions Based on Influent Loads and Flows and Treatment Cost

•  Track Equipment Performance – Drive Upgrades or Replacement

•  Track Treatment Performance and Assess Impact of Opera.onal Changes Before Ins.tu.ng

SUMMARY

26

• Two GeneraMon OpMons Considered


29

COST POWER OFFSET POWER EXPORT

Annual Engine O&M $50,000 $50,000

Essential Gas Cleaning $50,000 $50,000

Standby Charge $15,000 $0

Contract Demand Charge $36,000 $0

Natural Gas use $28,867 $28,867

Total Additional Costs $179,867 $128,867

Revenue/Cost Offset $354,705 $368,311

Net Revenue/Cost Offset $174,839 $239,444

Capital Costs $1.93M $2M

Simple Payback 11.1 years 8.4 years

• Benefits of a WW PS at MCWWTP •  Consolidates Transfer Pumping at One Loca.on •  Eliminates Mul.ple Transfer PS in System •  Flexibility in Future Treatment Op.ons •  Management of Industrial Users on U.lity Basis v.

Plant Basis

• Cost Impacts • Nominal Capital Cost Increase over Influent PS •  Lower Pump Head than Exist. South Fork PS • Allows TreaMng Flow at Most Cost EffecMve Plant

BACKGROUND – WASTEWATER SYSTEM FINAL LONG TERM WWTP OPTION

30

managing%multiple%variables:%%% … · natural gas use $28,867 $28,867 total additional costs...

Documents