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OWASA Mason Farm WWTP Optimization Program
“PUTTING THE EXTRA IN THE ORDINARY”
A public, non-profit agency providing water, sewer and reclaimed water services to the Carrboro-Chapel Hill Community.
Raleigh
Charlotte
Greensboro
Fayetteville
Wilmington
Chapel Hill/Carrboro, NC
Durham
Orange Water and Sewer AuthorityCommunity owned utility providing water, sewer and reclaimed water services to the Carrboro-Chapel Hill community in North Carolina.
Asheville
Mason Farm Wastewater
Treatment Plant
OWASA manages wastewaterTHE WASTEWATER MANAGEMENT SYSTEM
Customer Manhole Pumping Headworks PrimaryClarification
AerationBasins
SecondaryClarification Filtration Disinfection Morgan Creek
Reclaimed Water to UNC
AnaerobicDigesters
Biosolids toLand Application
WWTP PROCESS SCHEMATIC
Waste Activated Sludge
PreliminaryTreatment
Primary Sedimentation
IncomingWastewater
Gravity Belt Thickener
Digester 4 Biosolids
Storage
Biological Treatment FiltrationFinal
Sedimentation Disinfection
Sludge Fermenter
Re-aeration
LiquidBiosolids to
Land Application
Discharge to Morgan Creek or
Delivery for Use as Reclaimed Water
Primary Clarifier Sludge
Digester 3
Digester 2
Digester 1
Gravity Belt Thickener
Gravity Belt Thickener
Wastewater Treatment Process
Biosolids Treatment
RotaryPress
DewateredBiosolids toComposting
Filtrate
Implementing Organizational Change Can Be Challenging. . .
Implementing Organizational Change Can Be Challenging. . .
Yes, Sometimes Very Challenging. . .
- After Action Reviews (out of adversity comes opportunity)
- Comprehensive Emergency Management Planning
- Comprehensive Risk Assessment Planning
- Energy Management Planning
- Asset Management / CMMS / GIS Mapping
- CIP Prioritization / Replacement & Renewal Programs
OWASA – Culture of Continuous Improvement
- NACWQ Peak Performance Award – Platinum-7
- NC-DEQ Exceptionally Performing WWTP
- Energy Management Plan – Energy Management Team
- DOE – Energy Optimization On-Site Training
- High Performance SCADA (transitioning currently)
- On-Line Instrumentation (nutrients, MLSS, pH, ORP, DO)
- Real Time DO Control Strategy (nitrogen loading)
OWASA – Mason Farm WWTP
AWWA – PARTNERSHIP FOR CLEAN WATER
• Global optimization and recognition program for wastewater utilities– Wastewater treatment plants– Reuse facilities– Collection systems– Stormwater
Supporting All Optimization Efforts10. Stakeholder Understanding
andSupport
9. Water Resource
Sustainability Adequacy
8. Community Sustainability
7. EnterpriseResiliency
Operational6. Infrastructure
Strategy & Performance
Stability
5. Financial Viability
4. Operational Optimization
3. Employee and
Leadership Development
2. Customer Satisfaction
1.ProductQuality
Effective Utility Management
Wastewater Optimization
Multiple-Barrier Approach
Program Phases
• Phase I – Commit and Subscribe• Phase II – Baseline Data Submission• Phase III – Self-Assessment• Phase IV (future) - Demonstrated optimization
PHASE I – COMMITMENT
PARNTERSHIP FOR CLEAN WATER
PHASE II- Baseline Data Collection
Key Optimization Data Points For Quantifying Treatment Plant Performance and Program Performance Including Effluent Quality
BOD5/CBOD5, Total Suspended Solids, Ammonia Nitrogen and Total Phosphorus
Plant Flow and Energy Consumption
PARNTERSHIP FOR CLEAN WATER
PHASE II- Baseline Data Collection (continued)
Total Sludge Mass Control – provides comprehensive data tracking/trending for biological process control
Partnership Optimization Performance Goals
BOD/CBOD5, TSS, NH3, TP < 95% permit limits
Sludge Mass Control +/- 15% theoretical vs. actual
OWASA MASON FARM WWTP - PLANT PERFORMANCE Influent Measurements Effluent Measurements Nutrients Discharged
CY 2016 CBOD5 TSS NH3-N TP ADF CBOD5 TSS NH3-N TP TN TPMonth (Milligram per Liter) (Milligram per Liter) (Lbs. \ Month)
January 280 322 29.1 6.43 7.698 <2.0 <2.5 0.19 0.05 11,105 40February 228 304 28.1 6.15 8.397 <2.0 <2.5 0.21 0.11 16,571 223March 226 240 27.0 5.46 7.046 <2.0 <2.5 <0.10 0.42 12,351 765April 255 269 32.3 6.23 6.720 <2.0 <2.5 <0.10 0.52 12,560 874May 223 286 27.1 6.26 6.087 <2.0 <2.5 <0.10 0.27 11,457 425June 239 270 25.9 5.80 5.389 2.1 <2.5 <0.10 0.18 6,620 243July 212 257 22.4 5.26 5.099 <2.0 <2.5 <0.10 0.71 7,158 936August 201 290 24.0 5.51 5.403 <2.0 <2.5 <0.10 0.49 8,088 684September 277 378 27.1 8.81 5.863 <2.0 <2.5 <0.10 0.51 8,288 748October 251 294 28.2 5.98 6.625 <2.0 <2.5 <0.10 0.31 9,061 531November 283 317 32.7 6.95 6.683 <2.0 <2.5 <0.10 0.48 9,845 692December 260 242 33.0 6.26 5.923 <2.0 <2.5 <0.10 0.65 9,954 995
AVERAGE 245 289 28.1 6.26 6.411 <2.0 <2.5 0.03 0.39 10,255 596Removal Efficiencies 123,058 7,156
> 99% > 99% > 99% 94% 409,448 10,188Annual Limits TN TP
NPDES Permit Limits Monthly Average
Weekly Average
Flow 14.5 MGD n/aCBOD5 4.0 mg/l 6.0 mg/l summer - April 1 - October 31
CBOD5 8.0 mg/l 12.0 mg/l winter November 1 - March 31TSS 30.0 mg/l 45.0 mg/l
NH3-N 1.0 mg/l 3.0 mg/l summer - April 1 - October 31NH3-N 2.0 mg/l 6.0 mg/l winter November 1 - March 31
Fecal Coliform 200/100 mL 400/100 mLTN Load 409,448 lbs./year annual loading limitTP Load 10,188 lbs./year annual loading limit
Optimization Performance Goals
CBOD5 < 3.8 mg/l
TSS < 28.5 mg/l
NH3-N < 0.95 mg/l
TP < 9,679 lbs.
PARNTERSHIP FOR CLEAN WATERPHASE III-Self Assessment
Treatment Plant Staff Will Perform Comprehensive Self-Assessments of Wastewater Treatment Plant Performance, Operations and Energy Consumption(use EPA Comprehensive Correction Program Framework)
Self Assessment Reports Will Be Peer Reviewed By Wastewater Utility Optimization Experts(Program Effectiveness Assessment Committee – PEAC)
Phase III - Self-Assessment
- In-House Initiative; Team Development- Input valued from ALL level of the organization
PARNTERSHIP FOR CLEAN WATER
PHASE III – SELF ASSESSMENT PROCESS
STEP 1 – Complete Performance Assessment
STEP 2 – Complete Capacity Assessment (determine if sizes of major unit processes are limiting performance)
STEP 3 – Complete Unit Process Performance and Energy Assessment (identify other aspects of unit process design limiting performance)
STEP 4 – Complete Operations Assessment (identify operational practices limiting performance)
PARNTERSHIP FOR CLEAN WATER
PHASE III – SELF ASSESSMENT PROCESS
STEP 5 – Complete Administration Assessment (identify administration practices limiting performance)
STEP 6 – Assemble & Prioritize Comprehensive List of Factors Limiting Performance (identify activities to address factors that will improve performance)
STEP 7 – Implement Performance Improvements
STEP 8 – Assess Performance Improvements
PHASE III – SELF ASSESSMENT
• Team-based self-assessment of:– Performance– Capacity– Unit Processes – including
process energy efficiency– Facility energy efficiency– Operations– Administration
EPA’s CCP structure continues to guide self-assessment procedures.
PHASE III – SELF ASSESSMENT
EPA’s CCP structure continues to guide self-assessment procedures.
• Unit processes:– Influent water– Preliminary/Primary treatment– Suspended growth– Attached growth– Secondary clarification– Nitrification/denitrification– Biological/chemical phosphorus
removal– Chlorine/UV disinfection– Tertiary treatment
PHASE III – SELF ASSESSMENT
Orange Water & Sewer Authority receives the PSW 10-Year Directors Award at ACE15
• Successful completion of the self-assessment process results in receipt of the program’s Directors Award– Positive messaging and utility
outreach
• Annual data submission process maintains performance accountability
FOSTERING A CULTURE OF CONTINUOUS IMPROVEMENT
• Setting goals– Initial effluent performance goals set at 95% of
permit requirements – OR– Utility determined performance goals for effluent
quality and additional desired parameters– Annual reduction in energy use
• Assessment questions are a starting point
CY18 Partnership for Clean Water Focus Areas
- Optimize Digester Gas Utilization in Boiler System for Digester Heating
- Optimize Bio-P process (reduce effluent TP to < or = to 0.25 mg/l)
- Optimize acetic acid & alum utilization for chemical effluent TP trim
- Optimize GBT thickener operations; optimize polymer utilization
- Optimize High Performance SCADA (including mobile applications)
- Continued focus efforts toward established biosolids recycling goals
- Update/Merge Standard Operating Procedures and Process Control Protocols
- In-house maintenance & calibration of on-line process control instrumentation
OWASA MASON FARM WWTP - PLANT PERFORMANCE Influent Measurements Effluent Measurements Nutrients Discharged
CY 2016 CBOD5 TSS NH3-N TP ADF CBOD5 TSS NH3-N TP TN TPMonth (Milligram per Liter) (Milligram per Liter) (Lbs. \ Month)
January 280 322 29.1 6.43 7.698 <2.0 <2.5 0.19 0.05 11,105 40February 228 304 28.1 6.15 8.397 <2.0 <2.5 0.21 0.11 16,571 223March 226 240 27.0 5.46 7.046 <2.0 <2.5 <0.10 0.42 12,351 765April 255 269 32.3 6.23 6.720 <2.0 <2.5 <0.10 0.52 12,560 874May 223 286 27.1 6.26 6.087 <2.0 <2.5 <0.10 0.27 11,457 425June 239 270 25.9 5.80 5.389 2.1 <2.5 <0.10 0.18 6,620 243July 212 257 22.4 5.26 5.099 <2.0 <2.5 <0.10 0.71 7,158 936August 201 290 24.0 5.51 5.403 <2.0 <2.5 <0.10 0.49 8,088 684September 277 378 27.1 8.81 5.863 <2.0 <2.5 <0.10 0.51 8,288 748October 251 294 28.2 5.98 6.625 <2.0 <2.5 <0.10 0.31 9,061 531November 283 317 32.7 6.95 6.683 <2.0 <2.5 <0.10 0.48 9,845 692December 260 242 33.0 6.26 5.923 <2.0 <2.5 <0.10 0.65 9,954 995
AVERAGE 245 289 28.1 6.26 6.411 <2.0 <2.5 0.03 0.39 10,255 596Removal Efficiencies 123,058 7,156
> 99% > 99% > 99% 94% 409,448 10,188Annual Limits TN TP
NPDES Permit Limits Monthly Average
Weekly Average
Flow 14.5 MGD n/aCBOD5 4.0 mg/l 6.0 mg/l summer - April 1 - October 31
CBOD5 8.0 mg/l 12.0 mg/l winter November 1 - March 31TSS 30.0 mg/l 45.0 mg/l
NH3-N 1.0 mg/l 3.0 mg/l summer - April 1 - October 31NH3-N 2.0 mg/l 6.0 mg/l winter November 1 - March 31
Fecal Coliform 200/100 mL 400/100 mLTN Load 409,448 lbs./year annual loading limitTP Load 10,188 lbs./year annual loading limit
Optimization Performance Goals
CBOD5 < 3.8 mg/l
TSS < 28.5 mg/l
NH3-N < 0.95 mg/l
TP < 9,679 lbs.
2,600.00
2,700.00
2,800.00
2,900.00
3,000.00
3,100.00
3,200.00
FY12 FY13 FY14 FY15 FY16 FY17
MGD
6-Year WWTP Flow Summary
Total Flow Average Flow
7.6 MGD
8.1 MGD
8.3 MGD
8.1 MGD
8.6 MGD
8.5 MGD
0.00
5.00
10.00
15.00
20.00
25.00
30.00
FY12 FY13 FY14 FY15 FY16 FY17
MGD
6-Year WWTP Max Day Flow Summary
Max Day Average
12.1
22.3
20.1
15.0
23.2
27.4
0.000
10.000
20.000
30.000
40.000
50.000
60.000
FY12 FY13 FY14 FY15 FY16 FY17
MGD
6-Year WWTP Peak Hourly Flow Summary
Peak Hourly Flow Average
24.603
39.63437.558
27.961
49.60947.179
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
16,000,000
FY12 FY13 FY14 FY15 FY16 FY17
KWH
WWTP Electricity Usage
Total KwH Average
7,950,000
8,000,000
8,050,000
8,100,000
8,150,000
8,200,000
8,250,000
8,300,000
8,350,000
8,400,000
FY15 FY16 FY17
KWH
WWTP Electricity Usage - Post Aeration Project
Total KwH Average
126,000 KWH reduction in FY17
0.0000
0.5000
1.0000
1.5000
2.0000
2.5000
3.0000
3.5000
JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN
KWH/
1,00
0 ga
l.
FY15
FY16
FY17
Linear (FY17)
WWTP Electricity Usage – KWH/1,000 gal.
$0.00
$10,000.00
$20,000.00
$30,000.00
$40,000.00
$50,000.00
$60,000.00
$70,000.00
$80,000.00
FY12 FY13 FY14 FY15 FY16 FY17
Natural Gas Use - Digester Heating
0
5
10
15
20
25
January February March April May June
PROCESS CONTROL - SRT and ASRT
SRT (days) SRT (avg) ASRT (days) ASRT (avg)
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
160,000
180,000
2011 2012 2013 2014 2015 2016 2017
Lbs.
TP
Lbs.
TN
Calendar Year
EFF Nutrient Loading
TN
TP
Linear (TN)
Linear (TP)
2017 Forecast thru Oct. 2017
0
1
2
3
4
5
6
7
FY 12 FY 13 FY 14 FY 15 FY 16 FY 17
%TS Thickening Optimization
GBT DIG AVG AVG Linear (GBT) Linear (DIG)
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
CY 12 CY 13 CY 14 CY 15 CY 16 CY 17
Biosolids - Land Applied vs. Dewatered
Land Applied Dewatered Linear (Land Applied) Linear (Dewatered)
0
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
6,000,000
7,000,000
8,000,000
9,000,000
FY13 FY14 FY15 FY16 FY17
Gal
lons
Fiscal Year
Gallons Biosolids Dewatered
0.00
2.00
4.00
6.00
8.00
10.00
12.00
FY13 FY14 FY15 FY16 FY17
Wet
Ton
sDewatered Biosolids - Wet Tons/Box
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
400.00
450.00
500.00
$0.00
$20,000.00
$40,000.00
$60,000.00
$80,000.00
$100,000.00
$120,000.00
$140,000.00
$160,000.00
$180,000.00
$200,000.00
FY11 FY12 FY13 FY14 FY15 FY16 FY17
Use
(Ton
s)
Tota
l Cos
tWWTP - Caustic Use & Cost Summary
Caustic Cost Caustic Use Linear (Caustic Use)
0
100
200
300
400
500
600
700
$0.00
$20,000.00
$40,000.00
$60,000.00
$80,000.00
$100,000.00
$120,000.00
$140,000.00
$160,000.00
$180,000.00
FY11 FY12 FY13 FY14 FY15 FY16 FY17
Use
(Ton
s)
Tota
l Cos
t
WWTP - Alum Use and Cost Summary
Alum Cost Alum Use Linear (Alum Use)
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
1,600,000
1,800,000
$0.00
$50,000.00
$100,000.00
$150,000.00
$200,000.00
$250,000.00
FY11 FY12 FY13 FY14 FY15 FY16 FY17
Use
(Pou
nds)
Tota
l Cos
tWWTP - Acetic Acid Use & Cost Summary
Acetic Acid Cost Acetic Acid Use Linear (Acetic Acid Use)
0
10,000
20,000
30,000
40,000
50,000
60,000
$0.00
$5,000.00
$10,000.00
$15,000.00
$20,000.00
$25,000.00
$30,000.00
$35,000.00
FY11 FY12 FY13 FY14 FY15 FY16 FY17
Use
(Gal
lons
)
Tota
l Cos
tWWTP - Hypo Use & Cost Summary
Hypo Cost Hypo Use Linear (Hypo Use)
0
10,000
20,000
30,000
40,000
50,000
60,000
$0.00
$10,000.00
$20,000.00
$30,000.00
$40,000.00
$50,000.00
$60,000.00
FY14 FY15 FY16 FY17
Use
(Pou
nds)
Tota
l Cos
tWWTP - GBT Polymer Use & Cost Summary
GBT Polymer Cost GBT Polymer Use Linear (GBT Polymer Cost)
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
$0.00
$20,000.00
$40,000.00
$60,000.00
$80,000.00
$100,000.00
$120,000.00
$140,000.00
FY11 FY12 FY13 FY14 FY15 FY16 FY17
Use
(Pou
nds)
Tota
l Cos
tWWTP - RP Polymer Use & Cost Summary
RP Polymer Cost RP Polymer Use Linear (RP Polymer Use)
HIGH PERFORMANCE SCADA
Situational awareness – Blood test example
Source: High-Performance HMI Handbook
Is Fluffy sick?
Better SCADA Practices - Graphic StandardsHIGH PERFORMANCE SCADA
Situational awareness – Data in context made useful
Source: High-Performance HMI Handbook
Better SCADA Practices - Graphic StandardsHIGH PERFORMANCE SCADA
Color and Attention
Color is a powerful way to guide attention- Your eye is automatically drawn to colored
objects - “pop out” effect
How many “L”s and “I”s are in this picture?
- The Effectiveness of the Pop Out Effect drops dramatically as additional colors are added.
How many “L”s and “I”s are in this picture now?
Better SCADA Practices - Graphic StandardsHIGH PERFORMANCE SCADA
CY18 Partnership for Clean Water Focus Areas
- Optimize Digester Gas Utilization in Boiler System for Digester Heating
- Optimize Bio-P process (reduce effluent TP to < or = to 0.25 mg/l)
- Optimize acetic acid & alum utilization for chemical effluent TP trim
- Optimize GBT thickener operations; optimize polymer utilization
- Optimize High Performance SCADA (including mobile applications)
- Continued focus efforts toward established biosolids recycling goals
- Update/Merge Standard Operating Procedures and Process Control Protocols
- In-house maintenance & calibration of on-line process control instrumentation
OWASA Mason Farm WWTP Optimization Program
“PUTTING THE EXTRA IN THE ORDINARY”
QUESTIONS - ?
Opportunities to Optimize Performance – Headworks
- Headworks (influent pumping, bar screening and grit removal unit processes provide adequate capacity to manage design annual average and peak hourly flows
- Influent pump VFD obsolete, planned replacements needed
- Back-up level monitoring is needed; locate remotely in VFD control room
- Influent flow metering parshall flume area showing signs of significant corrosion due to covers
- Influent flow metering includes recycle streams; account for those flow accordingly to provide true raw influent flow metering
- Evidence of corrosion in Morgan Creek PS; include in comprehensive coatings program
- Re-balance odor control airflow from headworks area; verify design airflow and exchanges are provided to affected areas
- Create valve exercising program; provide for routine exercising
- Install power monitors on influent pumps; leverage data to also assist maintenance in providing key diagnostics to assess pump performance
- Provide proper vac truck off-loading station to capture debris prior to discharge into Morgan Creek PS
Opportunities to Optimize Performance – Headworks
- Enhanced public education and outreach regarding not using the toilet as a trash can; specifically proper disposal of grease & disposable wipes
- Evaluate whether accumulated grease in Morgan Creek PS can be captured, screened, liquefied and pumped to digesters
- Rehab bar screen #1 and #4 similar to recent rehab of bar screen #2
- Evaluate adjusting conveyor belt run time; avoid running when no screening debris is on belt
- Investigate whether consolidated screenings press can be designed; or even compacting dumpster – addresses on-going challenges with existing screening compactors (especially in winter months)
- Evaluate other dumpster options (screenings & grit) and log tonnage of each to landfill monthly
- Evaluate merits of installing baffle in vortex grit chamber to enhance performance; especially for smaller micron grit (Smith & Loveless)
- Evaluate how to effectively bypass primary clarifiers; requires getting flow to alternate weir height – this will be necessary to address corrosion/coatings repairs to primary splitter box #1
Opportunities to Optimize Performance – Primary Clarifiers
- Primary clarifiers provide adequate capacity to manage design annual average and peak hourly flows
- Hydraulic bottleneck exists in splitter box #2 during extreme wet weather flows
- Evaluate/repair north slide gate in splitter box #2 – needed for wet weather flow management
- Evaluate how to effectively bypass primary clarifiers; this will be necessary to address needed corrosion/coatings repairs to primary splitter box #1 and #2
- Address primary sludge pumping limitations to provide ability to pump thicker solids; impact fermenter operations (mixing and detention time)
- Primary clarifier scum pump stations needed rehab
- Primary clarifier #3 significantly impacted with grit accumulation after extreme wet weather events
- Rebalance odor control airflow; insure adequate airflow and exchanges are provided for clarifiers and splitter boxes
- Evaluate primary clarifier performance relative to influent CBOD value to biological process to insure for target F/M and also evaluate COD value relative to whether primary effluent/sludge could be viable food source to Bio-P process