Wastewater Treatment Consulting Engineering: P&IDs, Startups & Other

Considerations

William Marten, P.E., BCEE

December 6, 2010

UW-Madison CEE 426

®

What We’ll Cover (in a roundabout way):

• P&IDs• Plant Startups• Some Personal Career Experiences• Some Things to Consider as You Start

Your Careers

So What’s a P&ID?• Process & Instrumentation Diagram• Detailed Process Flow Diagram

– Includes Information on Tanks, Equipment & Instrumentation to Monitor & Control

– Sometimes Includes More Detailed Information • Serves as “Roadmap” of the Treatment Systems• Serves as Communication Tool (of How the

System is Intended to Work) for– Designers– Contractors– Owners/Operators– Regulators

P&IDs Are Developed as a Project Progresses

• Planning• Preliminary

Design• Final Design

• Construction

• Startup

• Process Flow Diagram• Unit Process

Interface/Preliminary P&IDs• Finalize P&IDs/Write Loop

Descriptions/Control Narratives• Revise P&IDs & Controls Based

on Constructability• Revise P&IDs & Controls Based

on Operability/Functionality

Process Flow Diagrams

Several Important P&ID Sheets

• Legend Sheets– Help Define What Abbreviations & Symbols

Mean• Unit Process Interface Summary

– Shows How Unit Processes Are Interrelated

– Tells What PID Sheet(s) Cover Specific Unit Processes

PID Legend Sheet

PID Legend Sheet 2

Unit Process Interface

Example P&ID

P&IDs Need Loop Descriptions (Control Narratives) for Detail

• Typically Part of I&C Specifications• Verbal Descriptions of Control System

Functions at Each “Control Level”– Local– Remote Panel Manual– Remote Panel Automatic– PLC/Computer OIU (Operator Interface Unit)

• Used to Program Controls & Displays at PLCs & OIUs

Another Example P&ID

Related Loop Description

What’s Up With Startups?

• Critical Time in any Project– Where the “Rubber Meets the Road”– Where the Owner/Operator(s) Finally Find

Out What They’re REALLY GETTING• Startups Need to be Planned & Executed

Effectively• Startups Can Determine Success/Failure

of Any Project

What’s Involved in a Startup?• Inspection – Startup Punchlist

– List of What Needs to be Done (Process & Non-Process)

– Assigns Responsible Party– Defines Priority– Tracks Status

• Facility/Equipment/System Checkouts– Continuity Testing– Performance Testing– Control System Testing

• Actual Startup Activities

Example Startup PunchlistSun Prairie WPCF Activated Sludge System Startup Punchlist Priority Key: 1 Must Be Confirmed Complete at Least 3 Days Before Startup

Update: 08/21/06 2 Must Be Complete by Time of Startup3 Must Be Complete Within 1 Week of Startup4 Can Be Completed After Startup

Item No. Item Date Identified Priority Responsible Party Status Tag No. Location Comments

1 Aeration basin D.O. probes not installed. 08/17/06 1 Aeration Basins Need to be installed, calibrated and checked for proper operation.

2 Aeration basin D.O. probe wiring not complete. 08/17/06 1 Aeration Basins Terminations need to be complete, checked and junction boxes sealed.

3 Aeration tank airflow meter wiring not complete. 08/17/06 1 Aeration Basins Terminations need to be complete, checked and junction boxes sealed.

4 Aeration tank air flow control valves not complete. 08/17/06 1 Aeration Basins Terminations need to be complete, checked and junction boxes sealed.

5 Ensure Entire Secondary Treatment Control System Controls Installed/Operational 08/17/06 1 Control System

6 Resolve/Revise Blower Automatic Startup Concept 08/17/06 1 Control System Do we really want automatic startup of blowers?

7 Resolve/Revise Blower Pressure Control Strategy 08/17/06 1 Control System Hand versus Automatic - resolve what setpoint & pressure transmitter used.

8 Revise RAS Pump Flow Control Strategy to Input Number Clarifiers Operating 08/17/06 1 Control System RAS flow pacing target based on 1 or 2 clarifiers in service.

9 Separate RAS PID/RAS Purge Control Screens 08/17/06 1 Control System Have RAS PID screen on a rarely or security protection screen.

10 Revise Aeration Basin FCV Minimum Airflow "Valve Clamp" Strategy 08/17/06 1 Control System Provide minimum position locks to prevent low air flow/surge condition in blowers.

11 Revise Aeration Basin FCV Maximum Airflow "Valve Clamp" Strategy 08/17/06 1 Control System Don't understand control logic

12 Provide written control system loop/functionality descriptions. 08/17/06 1 Control System Need all control levels & operations documented in writing prior to startup.

13 Revise Overall Aeration Basin FCV Airflow "Valve Clamp" Strategy 08/17/06 1 Control System Clamps based on airflow signals, not on valve position.

14 Ensure WAS holding (GBT feed) tank aeration system operational. 08/17/06 1 GBT

15 Resolve Blower Electric Power Surge Incident 08/17/06 1 Sec Control Bldg Explain what happened, how to prevent in future.

16 Blower #4 Not Installed 08/17/06 1 Sec Control Bldg Need all blowers operational & available.

17 Resolve Blowers Not Able to be Started 08/17/06 1 Sec Control Bldg Reported that one or more blowers won't start or run. Need all blowers operational.

18 Resolve Blower Fuses Blown Out 08/17/06 1 Sec Control Bldg May be related to item # 15.

19 Blower termination/wiring boxes need to be closed up. 08/17/06 1 Sec Control Bldg

20 Secondary Control Bldg scum pit level controls not installed. 08/17/06 1 Sec Control Bldg Clarification request related to installation rating.

21 Secondary scum pumps power wiring boxes need to be sealed. 08/17/06 1 Sec Control Bldg

22 Secondary scum pumps discharge pressure switches not wired. 08/17/06 1 Sec Control Bldg

23 WAS pump power wiring boxes need to be sealed. 08/17/06 1 Sec Control Bldg

24 RAS pump local/remote handswitch wiring boxes need to be sealed. 08/17/06 1 Sec Control Bldg

25 RAS pump coupling guards need to be installed. 08/17/06 1 Sec Control Bldg

26 Ensure RAS & WAS flowmeters are operational & calibrated. 08/17/06 1 Sec Control Bldg

27 Install PIT0751 on Blower Discharge Header & Ensure Fully Functional 08/17/06 1 Sec Control Bldg

28 Selector Basin Mixers - Install & Check Rotation 08/17/06 1 Selector Report that some mixers operated in reverse when started up.

29 Line up ORP meter & other testing equipment for startup procedures. 08/17/06 2 Donohue NA

30 Provide City with list of testing & equipment requirements. 08/17/06 2 Operations

31 Secondary Control Bldg light fixtures not installed/operational. 08/17/06 2 Sec Control Bldg Need to be operational for startup.

32 Secondary Control Bldg HVAC equipment not running. 08/17/06 2 Sec Control Bldg Needs to be operational for startup.

33 Secondary clarifier gear box drive chain cover not installed. 08/17/06 2 Secondary Clarifiers Ensure chain properly lubricated before reinstalling cover.

34 Selector Basin Sluice Gate Operator Handles Missing 08/17/06 2 Selector

35 Ensure WAS thickening & TWAS pumping system operational. 08/17/06 3 GBT

36 RAS Valve Operator Boxes @ Selector - Wrong Color? 08/17/06 4 Selector Painted black, should be same as RAS piping color?

Startups Must Be Planned For…

• Development of Startup Plan– Defines Startup Roles & Personnel

Assignments– Defines Communications Protocol

Owner, Designer, Contractor, Inspection Staff– Outlines the Startup Activities (Sequence)

Pre-Startup Startup Post-Startup

– Develops Process Control Targets & Tools

Examples of Pre-Startup Activities

• System Checkouts– Manufacturer– Unloaded– Clear Water

• Training– Vendor/Manufacturer– Designer

• Arrange for Chemical Deliveries/Seed Sludge

• Define Data Collection/Testing Needs

• Define/Provide Process Analysis/Control Tools

Sun Prairie WPCF Activated Sludge Wasting CalculatorInstructions:Step 1: Input today's date.Step 2: Input today's MLSS and RAS concentrations and 30 minute settling volume.Step 3: Input the volume of WAS wasted from the system yesterday (units are gal/day).Step 4: Input yesterday's plant flow (units are MGD).Step 5: Check and adjust the Process Inputs as necessary (seasonal or maintenance adjustment).Step 6: Press "Ctrl" & "w" (lower case w) at the same time and the spreadsheet will update itself (only do this after entering the new values, and only do it once per day).Step 7: Note the target volume to waste from the activated sludge system. Using this target plus judgment and experience, input the volume to waste into the control system.Step 8: Check the values you entered and the results shown. If something looks wrong, close the file without saving, then open it again and start at Step 1. If everything looks ok, save the file and then close it.

Notes:Cells with blue bold font in yellow shading are daily inputs (cells B19 through B26).If there is no value to report for the blue bold cells, leave the cell blank (press "delete").Cells with black bold font in gray shading are process inputs that will likely change on a seasonal basis, or when basins are out of service (cell B29).Do not leave process input cells blank - must have a value entered in each of these cells.Cell with black bold font in aqua shading gives target wasting volume for the day in gal/day.

Daily Inputs Date: 09/18/06MLSS Concentration (mg/L): 730

RAS Concentration (mg/L): 1,06330 Minute Settling Volume (mL): 100

Yesterday's WAS Flow: 24,000

Process InputsTarget Aerobic Sludge Age (days): 12.0

Aerated Basins in Service (1, 2 or 3): 1

Today's Wasting Target (gal/day): 48,480

System MonitoringActual Sludge Age - 7 Day R.A. (days): 14.2Actual MLSS Conc - 7 Day R.A. (mg/L): 553

30 Minute Yesterday's Today'sMLSS RAS/WAS Settling Volume WAS Flow SVI MLSS RAS/WAS SVI WAS Flow Today 7 Day R.A.mg/L mg/L mL gal/day mL/g mg/L mg/L mL/g gal/day LBS LBS

09/18/06 730 1,063 100 24,000 137 553 871 115 8,001 7,001 4,22409/18/06 730 1,063 100 24,000 137 528 843 114 6,546 7,001 3,97109/17/06 24,000 110 494 806 110 4,801 4,121 3,66809/16/06 24,000 110 494 806 110 2,668 4,121 3,16009/15/06 787 1,103 75 1 95 494 806 110 1 7,548 3,55509/14/06 600 974 75 1 125 436 747 113 1 5,755 2,98409/13/06 529 912 52 1 98 395 690 110 1 5,074 2,52209/12/06 458 849 52 1 114 350 616 114 1 4,393 2,01209/11/06 350 648 44 1 126 296 500 115 1 3,357 1,41709/10/06 1 104 241 352 104 1 0 77009/09/06 1 120 241 352 104 1 0 1,15609/08/06 241 352 25 1 104 486 708 120 12,001 2,311 4,656

1, 2 or 3

7 Day Running Average Wasting Calculations

Date

7 Day Running Averages ML Under AerationToday's Values

For Reference:

Range of Typical Values4-20 days

1,200-3,500 mg/L2,000-10,000 mg/L

70,000-300,000 gal/day

Startup Activities

• Process Setup – Set Valves and Equipment for Process Flow Train

• Startup Sequence & Procedures• Staff Assignments• Initiate Process Sampling/Testing• Log Book to Track All Activities

Successful Projects Require Effective Communications

• Owner Understanding– Process Expectations vs. Reality

• Contractor Understanding– Control of Change Orders

• Design Team– Design Meets Intent

Effective Communications (Written, Verbal) Starts At Planning and Never Ends

A Little Bit About Consulting Career Paths• Project Delivery

– Project Management– Production (Doing the Work)– Technical Expert

• Business Development/Marketing– Client Manager– Sales Manager

• Administrative– Supervisory– Office Management– Corporate Management

What Should You Be Looking For?

• OJT (On the Job Training) Opportunities– Project Opportunities (Cradle to Grave)– Mentors– Furthering Your Education

• Ability to “Know Yourself” & Grow into Yourself– Career Path Flexibility

• Does The Firms Business Goals Match Your Interests?

• What are the Time/Travel Opportunities & Demands?

• Does the Firm Support Professional Society Activities?

What Background Do You Need?

• Sound Understanding of Engineering, Hydraulics & Process Fundamentals

• Knowledge of Complementary Disciplines– Civil, Structural, Mechanical, Electrical

Power, Instrumentation & Control• Computer Skills a Must

– Including CADD Skills• Good Writing & Interpersonal Skills a Plus

What Are Employers Looking For?

• Sound Educational Foundation• Hard Workers

– Willing to Try New Things– Willing to Get Involved in “Outside”

Activities• Communicators – Written and Verbal• People Skills• Organization Skills

What to Look Out For….

• Firms trying to serve markets outside their area of expertise.

• Firms only interested in making a buck.– (versus serving client’s needs most

effectively)• Firms overly dependent on market

conditions– “Hire & Fire” versus conservative growth

Final Words of Encouragement

• Work Hard• Have Fun• Try to Learn New Things• Get Involved in Professional Societies• Look For Mentors