02 success with center-lining at wausau paper towels & tissues wwtp
DESCRIPTION
02 Success With Center-lining at Wausau Paper Towels & Tissues WWTPTRANSCRIPT
Success with Center-Lining at
Towel & Tissue Wastewater Treatment Plant
January 2014
Presenters
• Shawn Holler, WW III licensed operator has over 20 years of experience at Wausau Paper and in wastewater operations.
• Patty Bradley, Utilities Asset Leader & WW III licensed operator, has 13 years experience at Wausau Paper.
Presentation Topics
• What is center-lining and process behavior charting (PBC)?
• Improved Process Control & Management• Center-lining as a communication tool with
the rest of the facility operations• Benefits of better communication
• Wausau Towel & Tissue LLC is a provider of “away from home” towel and tissue products.
• Our vision is to be The Leading provider of environmentally sensitive products to the markets we serve.
The Middletown “Big 4” Focus
Injury Free Culture Through
Improved Processes and Engagement
of all
ReliableConsistently
delivering when expected
StableProcess in control with
only common cause variation
CapableClearly meeting
customer requirements
Business Excellence
Through Reliable, Stable, Capable
Processes
16% ROCE
Fiber
SpendingOEE
16 % ROCE Through
Successful Competitive
Improvement Plans
Environmental Sustainability and Growth Aligned with the EcoSoft
Brand
Sustainability & Growth - EcoVision
EcoVisionEcoVisionWe will be the leading provider of paper based, environmentally sensitive brands and solutions to the markets we serve.
The Middletown Mill has developed a vision and 5-year plans to enhance our Green Stewardship and Sustainability.
Improvement Areas Addressed Emissions free – air emissions reductions including green house gases Natural resource reduction – best in class water, fiber, and energy use Effluent discharge improvements – effluent quality better than river Waste disposal reductions – elimination or beneficial use of waste streams Community relations and outreach
What is Center-Lining?
• We developed a list of controllable parameters (centerlines) and a list of outcome parameters (in-process) that were tracked each shift and reported each day.
• Each parameter has a range or limit to be measured against as “in compliance”.
• Each day the percent “in-centerline” and percent “in-process” are recorded and calculated by the WWTP operators.
WWTP IN-PROCESS & CENTERLINE DAILY SHEETS
Middletown Mill
Date: November 16, 2013Q:/WWTP/WWTP-7yr
IN-PROCESS for Final Effluent Process Variable Target Actual Value
1ST SHIFT 2ND Shift 3RD SHIFT CommentsHighlight all deviations
Final Effluent Flow ≤ 4.7 MGD 4.34 X X Recycle Flow ≥ 1.0 MGD 1.43 X X
pH 7 < x < 8.5 S. U. 7.84 X X
D.O. > 5.0 mg/L X X
TSS < 200 mg/L 20 X X
COD < 225 mg/L 44 X X
Front AB Temperature (average) < 32 C 22.00 X 23.60
Conveyor Cake Solids ≥ 47% 48.0% X 52.3%
% In-Process 100% 100% 100%
QSF 3.1 WWTP CENTERLINE REPORT
WWTP IN-PROCESS and CENTERLINE DAILY SHEETS - Continued
CENTERLINESComments
Process Variable Target 1ST Shift 2ND Shift 3RD SHIFT Highlight all deviations
# 1 AB D.O. - end ≥1 ppm 4.98 X 2.81
# 2 AB D.O. - end ≥1ppm 4.39 X 2.22
# 1 AB D.O. - middle (probe) ≥ 2 ppm 4.27 5.59 5.37
# 2 AB D.O. - middle (probe) ≥ 2 ppm 3.38 3.93 3.57
Nutrient addition: UREA 125 - 150 gal X X 123
Nutrient addition: H3PO4 20 - 30 gal X X 21
MLSS concentration 2600 - 4000 mg/L 3385 X 3560
RAS concentration 6000 - 8500 mg/L 8380 X 8500
# 1 AB Settleometer ≤ 600 380 X 340
# 2 AB Settleometer ≤ 600 290 X 220
# 1 AB SVI < 250 98 X 87
# 2 AB SVI < 250 99 X 69
# 1 Sec. clarifier bed depth < 5 ft 2' 6" 2' 6'' 2'6"
# 2 Sec. clarifier bed depth < 5 ft 2' 6" 2' 0'' 3'0"
F / M 0.10 - 0.25 0.17 X 0.14
PRI torque ≤ 7 0 2 0
TH torque ≤ 7 2 1 0
Total Possible In-Centerline 15 6 17 38
Actual In-Centerline 15 6 17 38
% In-Centerline 100% 100% 100% 100%
What is process behavior charting?• Process behavior charting is the statistical trending of the system
data collected for the center-lining process to look at longer term variation.
• Sigma XL (excel) is used by Wausau Paper to produce process behavior charts of the data.
• The trends produced by Sigma XL show when statistical rules (i.e., upper and lower boundaries) are violated, indicating special cause versus common cause variation in our WWTP process.
• Process behavior charts are generated from process data and are referred to as the “voice of the process”.
• Trends are utilized to determine when changes should be implemented by being able to distinguish between normal variation (common cause) and special cause variations.
WWTP PBCsFinal Effluent TSS, mg/L
1
6
2
22
2
1
1
1
2
2
2
1
1
1
11
1
11
1
2
2
11
6
6
1
6
8
22
1 1
5
5
1
55
15
1
1
1
62
2
66
2
2
2
2
6
6
22222
2
2222
2
2
2
2
22
22222
22
2
222
2
5
62
2
666 2
22
2
2 2
2
2
2
1
1
5
Mean CL: 19.81
44.20
0
20
40
60
80
08/01
/12
08/15
/12
08/29
/12
09/12
/12
09/26
/12
10/10
/12
10/24
/12
11/07
/12
11/21
/12
12/05
/12
12/19
/12
01/02
/13
01/16
/13
01/30
/13
02/13
/13
02/27
/13
03/13
/13
03/27
/13
04/10
/13
04/24
/13
05/08
/13
05/22
/13
06/05
/13
06/19
/13
07/03
/13
07/17
/13
07/31
/13
08/14
/13
08/28
/13
09/11
/13
09/25
/13
Indi
vidu
als:
FE
TSS
(PPM
)
Food to Mass Ratio
1 1
55555
5
111
1
6666
2
1
1
86
1
5622
2
1
15
666
2
2
1
222
2
222222
2
2
1
5
666
2222
2
222
22
2
2
2
6666
22
2
2
22222222
2222222
66 666
6
6666
6
666
66
666
6
6
15
66
66666
1
2
2
222
2
2
26
6
6
62
Mean CL: 0.19
0.12
0.26
0.06
0.11
0.16
0.20
0.25
0.30
08/01
/12
08/15
/12
08/29
/12
09/12
/12
09/26
/12
10/10
/12
10/24
/12
11/07
/12
11/21
/12
12/05
/12 12
/19/12
01
/02/13
01
/16/13
01
/30/13
02
/13/13
02
/27/13
03
/13/13
03
/27/13
04
/10/13
04
/24/13
05
/08/13
05/22
/13
06/05
/13
06/19
/13
07/03
/13
07/17
/13
07/31
/13
08/14
/13
08/28
/13
09/11
/13
09/25
/13
Indi
vidu
als:
F:M
Improved Process Control & Management
• We better understanding of effluent quality at the WWTP based on understanding of the causes of variation & how conditions affect our process
Final Effluent TSS, mg/L
1
2
1
Mean CL: 24.80
-10.05
59.65
-20.00
-10.00
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
11/01
/13 11
/02/13
11/03
/13 11
/04/13
11/05
/13 11
/06/13
11/07
/13 11
/08/13
11/09
/13 11
/10/13
11/11
/13 11
/12/13
11/13
/13 11
/14/13
11/15
/13 11
/16/13
11/17
/13 11
/18/13
11/19
/13 11
/20/13
11/21
/13 11
/22/13
11/23
/13 11
/24/13
11/25
/13 11
/26/13
11/27
/13 11
/28/13
11/29
/13 11
/30/13
Indi
vidu
als:
FE
TSS
(PPM
)
Final Effluent COD, mg/L
1
Mean CL: 55.70
11.50
99.90
0.00
20.00
40.00
60.00
80.00
100.00
120.00
11/01
/13 11
/02/13
11/03
/13 11
/04/13
11/05
/13 11
/06/13
11/07
/13 11
/08/13
11/09
/13 11
/10/13
11/11
/13 11
/12/13
11/13
/13 11
/14/13
11/15
/13 11
/16/13
11/17
/13 11
/18/13
11/19
/13 11
/20/13
11/21
/13 11
/22/13
11/23
/13 11
/24/13
11/25
/13 11
/26/13
11/27
/13 11
/28/13
11/29
/13 11
/30/13
Indi
vidu
als:
CO
D m
g/L
WWTP PBCs# 1 AB Settleometer Sept - Oct. 2011
15
1
6
5 2
2 2 2
1
22 2
2 2
2
1
11
1
11
1 11
2 2
1
56 6
1
2 22 Mean CL: 623.85
489.95
757.74
350.00
400.00
450.00
500.00
550.00
600.00
650.00
700.00
750.00
800.00
9/3/20
119/5
/2011
9/7/20
119/9
/2011
9/11/2
0119/1
3/2011
9/15/2
0119/1
7/201
19/1
9/201
19/2
1/201
19/2
3/2011
9/25/2
0119/2
7/2011
9/29/2
01110
/1/20
1110
/3/20
1110
/5/20
1110
/7/20
1110
/9/20
1110
/11/201
110
/13/201
110
/15/201
110
/17/201
110
/19/201
110
/21/201
110
/23/201
110
/25/201
110
/27/201
110
/29/201
110
/31/201
1
Indi
vidu
als:
# 1
AB
Settl
eom
eter
# 1 AB Settleometer Nov. 2011
1
6
2
6 6
Mean CL: 428.00
336.53
519.47
320.00340.00360.00380.00400.00420.00440.00460.00480.00500.00520.00540.00560.00
11/1/
2011
11/2/
2011
11/3/
2011
11/4/
2011
11/5/
2011
11/6/
2011
11/7/
2011
11/8/
2011
11/9/
2011
11/10
/2011
11/11
/2011
11/12
/2011
11/13
/2011
11/14
/2011
11/15
/2011
11/16
/2011
11/17
/2011
11/18
/2011
11/19
/2011
11/20
/2011
11/21
/2011
11/22
/2011
11/23
/2011
11/24
/2011
11/25
/2011
11/26
/2011
11/27
/2011
11/28
/2011
11/29
/2011
Indi
vidu
als:
# 1
AB
Set
tleom
eter
Nutrient Additions
UAN Usage, gpd
Mean CL: 134.21
60.28
208.14
-50.00
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
400.00
8/1/20
128/6
/2012
8/11/2
0128/1
6/2012
8/21/2
0128/2
6/2012
8/31/2
0129/5
/2012
9/10/2
0129/1
5/2012
9/20/2
0129/2
5/2012
9/30/2
01210
/5/20
12
10/10
/2012
10/15
/2012
10/20
/2012
10/25
/2012
10/30
/2012
11/4/
2012
11/9/
2012
11/14
/2012
11/19
/2012
11/24
/2012
11/29
/2012
12/4/
2012
12/9/
2012
12/14
/2012
12/19
/2012
12/24
/2012
12/29
/2012
1/3/20
131/8
/2013
1/13/2
0131/1
8/2013
1/23/2
0131/2
8/2013
2/2/20
132/7
/2013
2/12/2
0132/1
7/2013
2/22/2
0132/2
7/2013
3/4/20
133/9
/2013
3/14/2
0133/1
9/2013
3/24/2
0133/2
9/2013
4/3/20
134/8
/2013
4/13/2
0134/1
8/2013
4/23/2
0134/2
8/2013
5/3/20
135/8
/2013
5/13/2
0135/1
8/2013
5/23/2
0135/2
8/2013
6/2/20
136/7
/2013
6/12/2
0136/1
7/2013
6/22/2
0136/2
7/2013
7/2/20
137/7
/2013
7/12/2
0137/1
7/2013
7/22/2
0137/2
7/2013
8/1/20
138/6
/2013
8/11/2
013
Indi
vidu
als:
UA
N U
sage
gal
Nutrient Additions
PO4 Usage, gpd
15 66
555688
2 6666666152222222222
8 66 22222 62222222222222222
1155156222222222222222
8185566
815
6655556 6556662222222222222221
86 22222 66
8 666666666666 66666666666666 222226 66666622222
1
6666666688
8 665562122222221
22222661666666666666
11521222212
2212121
Mean CL: 34.9617.79
52.12
-50.00-45.00-40.00-35.00-30.00-25.00-20.00-15.00-10.00-5.000.005.0010.0015.0020.0025.0030.0035.0040.0045.0050.0055.0060.0065.0070.0075.0080.0085.0090.0095.00100.00105.00110.00115.00120.00125.00130.00135.00140.00145.00150.00155.00160.00165.00170.00175.00180.00185.00190.00195.00200.00205.00210.00215.00220.00225.00230.00235.00240.00245.00250.00255.00260.00265.00270.00275.00280.00285.00290.00295.00300.00
8/1/20
128/6
/2012
8/11/2
0128/1
6/2012
8/21/2
0128/2
6/2012
8/31/2
0129/5
/2012
9/10/2
0129/1
5/2012
9/20/2
0129/2
5/2012
9/30/2
01210
/5/20
12
10/10
/2012
10/15
/2012
10/20
/2012
10/25
/2012
10/30
/2012
11/4/
2012
11/9/
2012
11/14
/2012
11/19
/2012
11/24
/2012
11/29
/2012
12/4/
2012
12/9/
2012
12/14
/2012
12/19
/2012
12/24
/2012
12/29
/2012
1/3/20
131/8
/2013
1/13/2
0131/1
8/2013
1/23/2
0131/2
8/2013
2/2/20
132/7
/2013
2/12/2
0132/1
7/2013
2/22/2
0132/2
7/2013
3/4/20
133/9
/2013
3/14/2
0133/1
9/2013
3/24/2
0133/2
9/2013
4/3/20
134/8
/2013
4/13/2
0134/1
8/2013
4/23/2
0134/2
8/2013
5/3/20
135/8
/2013
5/13/2
0135/1
8/2013
5/23/2
0135/2
8/2013
6/2/20
136/7
/2013
6/12/2
0136/1
7/2013
6/22/2
0136/2
7/2013
7/2/20
137/7
/2013
7/12/2
0137/1
7/2013
7/22/2
0137/2
7/2013
8/1/20
138/6
/2013
8/11/2
013
Indi
vidu
als:
Pho
s. A
cid
usag
e ga
l
Center-lining as a communication tool with other departmental operations
• We learned to communicate with the rest of the of the operation using the same “language”.
• WWTP Operators attend the morning mill meetings as “step-up” employees to discuss center-line data. The Operators see the centerline and in-process data presented by the other departments and the variation in those areas.
• At times, we are able to link their variation to our process data.
Center-lining Communication• Each area of the Mill communicates the stability of their
area in the morning meeting using the “centerline and in-process” terminology
Center-lining Communication
Benefits of Improved Communication
• Communication of data can be used to prevent upsets.
• Communication of data can be used to justify projects.
• Communication of data can be used to understand how process changes in the paper mill and deinking affect the stability and costs of the WWTP operations.
• Operations are working to support each other better, relying on facts (data) rather than emotion.
Projects and Process Changes • Installation of hydrogen peroxide system to prevent low dissolved
oxygen in the final effluent.• Installation of additional flighting to sludge screw press to increase
solids.• Installation of a new polymer system following polymer trials.• Reduction of fresh water usage in deinking. • Finding alternative outlets for residual paper. The bulk of the paper
sludge is now being used in liquid solidification for non-hazardous waste streams.
• Trial to reduce VOAs in primary and thickener clarifiers to improve treatment.
• Reduction of steam usage in paper machine applications during summer months to prevent temperature impact to microorganisms.
Secondary Clarification (June 2011)
Secondary Clarification (January 2014)