Transcript

Providing Infrastructure Redundancy at the Rocky River WWTP

Timothy McCann – AECOM

Keith Bovard – Rocky River WWTP

WWTP Infrastructure Redundancy

Redundancy

• As NASA Would Say:

“A Backup Plan for the

Backup Plan”

• Nuclear Power Plant

• Wastewater Treatment

Plant

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Infrastructure Redundancy

• Infrastructure Redundancy

Neglected in Early WWTPs

• Incorporated in New

Construction and

Rehabilitation

• Redundancy May or May

Not be Part of Normal

Operations

• Includes Piping, Tanks,

Channels, etc.

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Driving Forces for Redundancy

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Maintenance and Operation

Efficiency 38%

Regulations 29%

Emergency/ Disaster Planning

12%

Design Guidelines

21%

• Efficient Redundancy

Design Practices, 2003

• Survey of 46 Treatment

Facilities

Jank, Palmer, Ross 2003

Infrastructure Redundancy Benefits

• Reduced Downtime

• Meet Regulations

– Avoid Bypasses

– Provide Required Treatment

• Savings on O&M

– Avoid Maintenance Issues

• Increased Plant Operation

Efficiency

• Overall Cost Effectiveness

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Providing Infrastructure Redundancy

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Additional Redundancy Measures

• Backup or Standby

Equipment

– Pumps, Screening

• Spare Parts On-hand

• Instrumentation

Redundancy or Backup

Measures

– Sensors, Analyzers

• Emergency Contracts

– Sludge Disposal, Pumping

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Redundancy – 10 States Standards

• Sec. 53.6 – Arrangement of

Units

– Arrange units for O&M

convenience

– Flexibility and ease of

installation of future additions

– Continuous quality effluent

– Economical additions

• Sec. 54.2 – Unit Bypasses

– Maintenance & emergencies

– Maintain effluent quality

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Headworks and Preliminary Treatment

• Screening

• Grit Removal

• Equalization Tank

• Bypass Alternatives

• Redundancy or Backup

Measures

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Primary Treatment

• Primary Clarifiers

– Additional Tanks

– Replacement Equipment

• Influent & Effluent

Channels and Pipes

• Chemical Feed

– Storage

– Pumping

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Secondary Treatment

• Biological Treatment Tanks

– Additional Tanks

– Backup Equipment

• Bypass Channels and

Pipes

• Sludge Lines

• Secondary Clarifiers

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Advanced Treatment

• Bypass Channels and

Pipes

• Nutrient Removal

– Nitrogen

– Phosphorus

• Filtration

• Process Tanks

• Equipment

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Disinfection

• Bypass Channels and

Pipes

• Process Tanks

• Chemical Feed

• UV

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Solids Processing

• Digester Tanks

• Storage Tanks

• Bypass Piping

• Dewatering

• Gas Handling

• Disposal

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WWTP Infrastructure Redundancy

• What Works Best for YOU?

– Rotate Equipment

– Use Tanks, Channels as Part

of Normal Operations

– Emergency Use Only

• Tailor to Each Individual

Plant

• Operator Experience

– What Will Work?

– What is Needed?

• Engineering Guidance

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Rocky River WWTP Background and History

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Rocky River WWTP Information

• Serves 4 Communities

– Bay Village

– Fairview Park

– Rocky River

– Westlake

• Design Flow: 22.5 MGD

• Average Flow: 12.5 MGD

• Peak Influent Flow: 170

MGD

– February 2011

– All Flow Through Bar Screens

• Submerged Outfall

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1937 Plant

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1937 Plant Description

• Grit Chamber

• Settling Tank

• Anaerobic Digestion

• Sludge Drying Beds

• Discharge to Spencer Creek

• Provided Capacity & Function Until 1960s

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1961 Plant

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1961 Plant Modifications

• Additional Screening & Comminutor

• Aerated Grit Removal

• Chemical Coagulant Feed

• Primary Clarification

• Effluent Chlorination

• Submerged Outfall to Lake Erie

• Sludge Thickeners and Anaerobic Digesters

• Vacuum Filtration and Sludge Incinerator

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1961 Construction Photos

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1961 Construction Photos Cont.

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1975 Plant

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1975 Plant Modifications

• Ohio Water Pollution Control Board

– 1965 – Required Secondary Treatment

– Average Flow: 10 MGD

– Peak Flow:20 MGD

• Granular Activated Carbon Filtration & Adsorption

• Added Settled Sewage Pump Station to Carbon Facility

• Additional Minor Upgrades

• Carbon Treatment Operated Less than One Year

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Current Plant

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Current Plant

• Added four Fixed Film

Reactors & Final Clarifiers

• Chlorine Contact Tanks

• Modified Settled Sewage

Pump Station

– 45 MGD Capacity

– Four 15 MGD Pumps

– 42-inch Force Main to Reactor

Building

• Additional Clarifier Tanks

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Settled Sewage Pump Station Backup Project and Alternatives

Settled Sewage Pump Station

• Pumps Primary Treated

Wastewater to Secondary

Treatment

• Wet Well - Converted

Chlorine Contact Tank

• Rehabbed Carbon Column

Treatment Pump Station

• Flow from Primary

Clarifiers and Auxiliary

Clarifiers

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Plan View – Before Project

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Section View – Before Project

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SSPS Backup Project Purpose

• All Flow to Secondary

Treatment is through

Existing Force Main

• Potential Issues with Pump

Station – No Secondary

Treatment

– Pump Failure

– Force Main Failure

– Wet Well Issues

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SSPS Potential Additional Issues

• Prevent Permit Violations

• Die-off of Microorganisms

at Reactors

• Associated Odor Problems

(Proximity to Houses)

• Start-up Timeframe for

Reactor Activity

• Consequent Sludge

Volume Wash-out

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SSPS Backup – Alternative #1

Submersible Pumps in Wet Well

• Redundant Pump Capacity

– Two Submersible Solids Handling Pumps

– 15 MGD @ 80 feet TDH each

• Use Existing Force Main

• Simple Modification

– Existing station remain online

– No gates required

• Interfere with Normal Operating Conditions

– Must be stored somewhere else onsite

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Alternative #1

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SSPS Backup – Alternative #2

Redundant Pump Station

• New Pump Station

– Two Vertical Turbine Pumps

– 15 MGD @ 80 feet TDH each

• Use Existing Force Main

• New Wet Well Collection Box

• Stop Plates in Wet Well

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Alternative #2

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SSPS Backup – Alternative #3

Redundant Pump Station and Force Main

• New Pump Station

– Two Vertical Turbine Pumps

– 15 MGD @ 80 feet TDH each

• Construct New Force Main

• New Wet Well Collection Box

• Operation Flexibility

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Alternative #3

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Alternative #3 Continued

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SSPS Backup – Alternative #4

Contract Pumping Service

• Contract with Pump Rental Company

• Rent 30 MGD Pumping Capacity

– Pumps running and installed within 24 hours

– Full capacity within one week

• Run Temporary Force Main to Reactor Building

• Construct Permanent Piping at Reactor Building

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SSPS Backup – Alternative #5

Temporary Pumps and Wet Well Partition

• Similar to Alternative #4

• Contract with Pump Rental Company

• Rent 30 MGD Pumping Capacity

– Pumps running and installed within 24 hours

– Full capacity within one week

• Run Temporary Force Main to Reactor Building

• Construct Permanent Piping at Reactor Building

• Install Partition Gates in Wet Well

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Alternative #5

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Cost Comparison

$1,649,000

$3,127,000

$3,958,000

$655,000 $414,000

$0

$500,000

$1,000,000

$1,500,000

$2,000,000

$2,500,000

$3,000,000

$3,500,000

$4,000,000

$4,500,000

Alt. 1-Submersible

Pumps

Alt. 2-Backup Pump

Station

Alt. 3-Backup Pump

Station andForce Main

Alt. 4-Contract

Pumping Service

Alt. 5-Contract

Pumping & WetWell Partition

Alternative Cost Analysis

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Alternative Selection

• Selected Alternative #5

• Bypass Pumping Used

– Lift station rehabilitation in

case of lift station

malfunctioning, failure or force

main rupture.

• Bypass Work Accomplished

with Centrifugal Pumps

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Bypass Pumping Design

• Pump Capacity

– 35 MGD

• Piping Layout

• Permanent Pipe Design

• Flap Gate

• Picture of Permanent

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Design Project – Wet Well Modifications

• Added Slide Gates to Wet

Well

• Dividing Wall Slide Gate

• Additional Channel Gate

October 25, 2012 Providing Infrastructure Redundancy

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Additional Project Items

• Overflow Meter

• Pipe Painting

• Additional Level Sensors

– Split Wet Well

– SCADA Integration

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Ohio EPA Project Notification

• Preventative Backup System

• Purpose: Maintain Flow to Secondary Reactors in the

Event of a Failure to:

– Primary effluent pump station

– 42-inch force main.

• No Change to Treatment System

• Low Bidder: $650,000

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Settled Sewage Pump Station Backup Project Construction Phase

Permanent Pipe Construction

• Enable Connection of

Temporary Pipe at Ground

Level

• Empty into Reactor

Building Wet Well

• Multiple 18-inch

Connections with Knife

Gate Valves

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Bypass Pumps & Piping

• Dry Prime

– 6 Pumps – 7 MGD Each

• Welded HDPE Pipe

– 3-18” Pipes to Reactors

– Pipe Header

• Air Relief Valves

• Drain Lines

• Knife Gate Valves

• Check Valves

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Wet Well Preparation & Utilization

• Temporary Bulkhead

Portion of Wet Well

• Maintain Flow to Portion of

Wet Well for Bypass Pump

Intakes

• Allow Installation of Wet

Well Gates & Dividing Wall

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Wet Well Slide Gates & Divider Wall

• Divider Wall Construction

• Three New Slide Gates

• New Level Sensors

– Used Existing Conduit &

Spare Wiring

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Operations During Construction

• Equipped with Alarms to

Notify Operations Staff of

Unit Failure or Loss of

Power.

• SCADA

• Wet Well Levels and

Transformer Availability

• VFD Performance

• Pump Pressure

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Current Availability in Case of Emergency

• Some after-Project

equipment and materials

maintained onsite.

• Line item Budget reserved

for Emergency Contracts.

• Proposals received for

projected use of pumps

and piping equipment.

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Construction Challenges

• Permanent Pipe Pad

– Existing Unknown Duct Bank

• Permanent Piping

– Modification for New Flange

– Air Release

• Electric or Diesel Pumps?

• Wet Well Temporary

Bulkhead

• Noise & Spill Containment

• Bypass Demobilization

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Future Redundancy

Current Backup Systems

• Dual Primary (Single-stage) Digesters and Mixers, Thickeners and Sludge Heaters

• Two Belt Filter Presses, Polymer Systems, and Associated Feed And Washwater/Filtrate/Sump Pumps

• Pump Station Galleys with Multiple Pump and Piping Configurations

• Chemical Storage Tanks and Pumps

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Potential Future Redundancy

• Digestion

– Sludge Screening

– Storage Tanks

• Storm Tank Dewatering and Sludge Piping

• Additional Chemical Piping

• Water Main and Plant Circulation Piping

• Backup Generator

– Currently Second Power Source

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Questions? Thank You

Tim McCann: [email protected]

Keith Bovard: [email protected]

References

Janks B., Palmer T., Ross M. 2003. Efficient Redundancy Design Practices.

Alexandria, VA: Water Environment Research Foundation.

2004. Recommended Standards for Wastewater Facilities. Albany, NY: Wastewater

Committee of the Great Lakes--Upper Mississippi River Board of State

and Provincial Public Health and Environmental Managers


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